Dodge Ram Truck 1500-2500-3500. Manual — part 2055

INSTALLATION

SADEN A/C COMPRESSOR

CAUTION: The snap ring must be fully and prop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.

NOTE: A new snap ring must be used to secure
the clutch field coil to the A/C compressor. The
bevel side of the snap ring must face outward and
both snap ring eyelets must be oriented to the
right or to the left of the clutch field coil dowel pin
location on the A/C compressor.

1. Install the clutch field coil (1) and using snap ring

pliers (Special Tool C-4574 or equivalent) (2),
install the snap ring that secures the field coil to
the front of the A/C compressor. Be certain that the
snap ring is fully and properly seated in the groove.

2. Install the retainer and screw (3) over the wire har-

ness lead (2) of the clutch field coil (1) and onto
the A/C compressor. Tighten the screw to 2.2 N·m
(20 in. lbs.).

3. Position the pulley and bearing assembly (1)

squarely onto the front of the A/C compressor.

NOTE: Thread the installer fully onto the compres-
sor shaft. Turn the installer nut until the pulley and
bearing assembly is fully seated.

24 - 220

CONTROLS

DR/DH

4. Using installer (Special Tool C-6871 or equivalent) (2), install the pulley and bearing assembly.

CAUTION: The snap ring must be fully and prop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.

NOTE: A new snap ring must be used to secure
the pulley and bearing assembly to the A/C com-
pressor. The bevel side of the snap ring must face
outward.

5. Using snap ring pliers (Special Tool C-4574 or

equivalent) (2), install the snap ring that secures
the pulley and bearing assembly (1) onto the front
of the A/C compressor. Be certain that the snap
ring is fully and properly seated in the groove.

6. If the original clutch plate (1) and pulley and bear-

ing assembly are to be reused, reinstall the original
shim(s) onto the compressor shaft. If a new clutch
plate and/or pulley and bearing assembly are being
used, install a 1.0, 0.50, and 0.13 millimeter (0.040,
0.020, and 0.005 inch) shims from the new clutch
hardware package that is provided with the new
clutch.

7. Install the clutch plate onto the compressor shaft.

8. Insert the two pins of the spanner wrench (Special

Tool C-4489 or equivalent) (2) into the holes of the
clutch plate (1). Hold the clutch plate stationary and
install the nut that secures the clutch plate. Tighten
the nut to 20 N·m (15 ft. lbs.).

NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is correct. Spin the pul-
ley before performing a final check of the air gap.

9. With the clutch plate assembled tight against the

shim(s), measure the air gap between the clutch
plate and the pulley and bearing assembly faces
with a feeler gauge. The air gap should be between
specifications (Refer to 24 - HEATING & AIR CON-
DITIONING - SPECIFICATIONS). If the proper air
gap is not obtained, add or subtract shims as
needed until the desired air gap is obtained.

10. Install the bolts that secure the A/C compressor to

the mounting bracket (Refer to 24 - HEATING &
AIR

CONDITIONING/PLUMBING/COMPRES-

SOR-A/C - INSTALLATION).

DR/DH

CONTROLS

24 - 221

11. Connect the engine wire harness connector to the A/C compressor clutch coil.

12. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/BELTS-DRIVE - INSTALLATION).

13. Reconnect the negative battery cable.

DENSO A/C COMPRESSOR

1. Align the dowel pin on the back of the clutch field

coil (2) with the hole in the compressor front cover
(3) and position the clutch field coil onto the A/C
compressor. Be certain that the clutch coil wire har-
ness is properly oriented and routed so that it is
not pinched between the compressor front cover
and the clutch field coil.

CAUTION: The snap ring must be fully and prop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.

NOTE: A new snap ring must be used to secure
the clutch field coil to the A/C compressor. The
bevel side of the snap ring must face outward and
both snap ring eyelets must be oriented to the
right or to the left of the clutch field coil dowel pin
location on the A/C compressor.

2. Using snap ring pliers (Special Tool C-4574 or

equivalent) (1), install the external snap ring (4)
that secures the clutch field coil to the front cover
of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented
correctly.

3. Install the screw that secures the clutch field coil wire harness connector bracket and ground clip to the top of

the compressor housing. Tighten the screw securely.

CAUTION: When installing the pulley and bearing
assembly, DO NOT mar the friction surfaces of the
pulley or premature failure of the clutch will result.

4. Install the pulley and bearing assembly (1) onto the

front cover of the A/C compressor. If necessary, tap
the pulley gently with a block of wood (2) placed on
the pulley friction surface.

24 - 222

CONTROLS

DR/DH

CAUTION: The snap ring must be fully and prop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.

NOTE: A new snap ring must be used to secure
the pulley and bearing assembly to the A/C com-
pressor. The bevel side of the snap ring must face
outward.

5. Using snap ring pliers (Special Tool C-4574 or

equivalent) (2), install the external snap ring (1)
that secures the pulley and bearing assembly (3) to
the front cover of the A/C compressor. Be certain
that the snap ring is fully and properly seated in the
groove.

6. If the original clutch plate (2) and pulley and bear-

ing assembly are to be reused, reinstall the original
shim(s) (3) on the compressor shaft (1) against the
shoulder. If a new clutch plate and/or pulley and
bearing assembly are being used, install a trial
stack of shims 2.54 mm (0.010 in.) thick on the
compressor shaft against the shoulder.

DR/DH

CONTROLS

24 - 223