OEM 2002 Dodge Ram 3500 A/C Clutch

2002 Dodge Ram 3500 A/C Clutch Parts and Q&A

• Q: How to Replace the A/C Clutch on 2002 Dodge Ram 3500?

  A: Before you replace the A/C compressor clutch, make sure to first disconnect and isolate the negative battery cable. To service models with a diesel engine, remove the compressor from the engine without parting with the refrigerant lines. Take off the compressor clutch coil wire harness connector from the clamp base. Loosen the hex nut holding the clutch plate by first using Special Tool 6462 from Kit 6460 to keep the clutch plate in place. Clutch plate and shim removal should include using Kit 6460 Special Tool 6461 to safely extract the clutch plate--always making sure the shaft key is removed too on diesel types. Remove the external front housing snap ring with snap ring pliers, then place Special Tool C-6141-1 from Kit 6460 into the snap ring groove and set the shaft protector (Special Tool C-6141-2 from Kit 6460) in its place. Place the through-bolts (Special Tool C-6461) through the flange onto the puller jaws, tighten and turn the center bolt clockwise until the rotor pulley comes off. Release the screw and retainer from the clutch coil lead wire on the compressor front assembly and slide off the clutch field coil after taking off the snap ring from the hub. To install everything, put the clutch field coil and snap ring back, fit the retaining clip for the clutch lead wire harness onto the compressor front and set the rotor assembly onto the front compressor housing hub. Pass Special Tool 6464 from Kit 6460 through Special Tool 6143 from the same kit and position this tool assembly into the hole of the rotor encountering the bearing, so it lies on the inner race. Slide the driver toward the end of your shaft while steering the rotor and listen until an air-chainging sounds is heard when the rotor touches the hub of the compressor front housing. When inserting the snap ring on the front rotor, make sure the bevel faces outside, because this prevents the rotor from flying off and harming the clutch. Use Special Tool 6141-2 from Kit 6460 as an altimeter and listen for a difference in sound as you firmly push the clutch plate down while on the shims. Install and fasten the compressor shaft hex nut to 14.4 Nm (10.5 ft. lbs.). Test the air gap using a feeler gauge and add shims to make the gap between the clutch and the flywheel either 0.41 or 0.79 millimeter (0.016 or 0.031 inch). When the air gap is uneven, you can adjust it slightly by prying or tapping the pieces. When replacing the clutch, install the shims from the first time in place or if the compressor didn't come with a clutch, install the shims you find in the included kit. On cars with a diesel engine, put the compressor back on and attach the negative terminal of the battery again.