OEM 2004 Dodge Sprinter 2500 A/C Clutch

2004 Dodge Sprinter 2500 A/C Clutch Parts and Q&A

• Q: How to Service the A/C Clutch on 2004 Dodge Sprinter 2500?

  A: First, detach and isolate your battery's negative cable and next, take off the serpentine drive belt to access the compressor clutch. Unplug the engine wire harness from the clutch coil wire harness at the compressor top and unscrew the retainer that holds the compressor clutch coil lead. With the clutch disarmed, disconnect the bolt attaching the clutch to the compressor shaft using a band-type oil filter wrench if required. Lightly hit the clutch plate with a plastic mallet to separate it from the splines on the compressor shaft, but don't drop any shim(s). Use C-4574 snap ring pliers (or a similar set) to remove the outer snap ring pinning in the compressor clutch pulley and then pull it off. Compressor clutch coil-used with this tool-attached with external snap rings, pull the top outward with an appropriate tool to break connections. Key factors to inspect in the clutch are wear, signs of oil and bearings. Change these components when needed, especially the clutch pulley and clutch plate. Match the dowel pin axis on the back of the clutch field coil with the front cover hole and be sure the wire harness leads are in position. Slide the clutch coil back onto the sprocket using a new snap ring, so its bevel side is outward and sits properly. Screw and tighten the socket for the clutch coil wire harness bracket. Attach the pulley at the front of the compressor, placing a block of wood there if necessary and make certain the external snap ring is facing outward. For the clutch plate and pulley you reuse, replace the existing shim(s); for entirely new items, use one shim that is 1.0 mm (0.040 in.) thick. Mount the clutch onto the compressor shaft and fix the compressor shaft bolt so it is at 17.5 Nm (155 in. lbs.). Check the air gap afterward. Connect the retainer for the compressor clutch coil lead, attach the engine wire harness connector, belt the serpentine accessory drive back on and reconnect the battery negative cable. If you use new clutch components, they should be given a burnishing treatment.