OEM 2003 Dodge Sprinter 3500 A/C Clutch

2003 Dodge Sprinter 3500 A/C Clutch Parts and Q&A

• Q: How to Service and Repair an A/C Clutch on 2003 Dodge Sprinter 3500?

  A: Before touching the compressor clutch, disconnect and isolate the negative battery cable and next remove the drive belt. Separate the wire harness connector for the compressor clutch coil from the clutch coil on the top of the compressor and remove the clip from the wire harness compressor clutch coil wire lead on the compressor. Release the bolt connecting the clutch of the compressor to the compressor shaft and remove it using a band-type or strap oil filter wrench if required. Gently strike the clutch plate with a plastic mallet until it comes free from the splines on the compressor shaft and then take out the clutch plate and all the included shim(s). Place the Special Tool C-4574 or an equivalent on the outer snap ring near the compressor clutch pulley and twist to unhook it, then slide the pulley backward off the front of the compressor. Unlock the second and third screws on the compressor housing and the bracket and ground clip bolt and disconnect the snap ring from the coil wire harness to let the clutch coil slip off the compressor. Connect the dowel pin on the clutch coil with the hole in the compressor front cover. Then, slide the clutch coil onto the compressor so the wire harness leads are in the right place. The clutch coil should be secured with a new snap ring, with the beveled side directed outside the coil. Use a snap ring plier to secure the snap ring so that it is placed tightly into the slot to avoid worry of clutch failure. Attach both the clutch coil wire harness connector bracket and ground clip on top of the compressor housing. Set the pulley on the front of the compressor and if you find resistance, put a block of wood on the moving surface to help. Install the external snap ring with the bevel facing outward. Should you choose to use the old clutch and pulley, put the originals shims against the shoulder on the compressor shaft; however, if you use new components, put in a trial set of 1.0 mm (0.040 in.) thick shims. Install the clutch plate onto the compressor shaft and tighten the compressor shaft bolt to 17.5 N.m (155 in. lbs.), using a band-type oil filter wrench or strap wrench if you don't have a torque wrench. After tightening, examine the air gap in at least four locations and turn the pulley over just before the final check. New clutch components should be burnished if they are added. Clip the end of the retainer to the engine wire harness compressor clutch coil lead and match it to the bracket at the top of the compressor, then put back the engine wire harness connector, reinstall the serpentine accessory drive belt and connect the battery negative cable.