AC Clutch Coil

This procedure covers replacement of the AC compressor clutch coil on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine without removing the compressor from the vehicle.

Warnings

Tools required

Parts

• AC compressor clutch coil × 1 — Use OEM specification for 3.5L EcoBoost
• Snap ring (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery cable and wait 2 minutes
4. Raise and support front of vehicle on jack stands for better access from below
5. Remove engine splash shield/skid plate if equipped for improved compressor access
6. Clean area around AC compressor to prevent contamination

Procedure

1. 1

   Access AC compressor
   Locate the AC compressor on the passenger side lower front of the engine. Remove the serpentine belt by rotating the tensioner clockwise with a breaker bar or serpentine belt tool. Note belt routing before removal. The compressor is now accessible for clutch service.
2. 2

   Disconnect clutch coil electrical connector
   Locate the electrical connector on the front of the AC clutch coil. Press the retaining tab and pull the connector straight off the coil terminals. Secure the wiring harness away from the work area.
3. 3

   Remove clutch coil retaining snap ring
   Using snap ring pliers, carefully remove the large snap ring that secures the clutch coil to the compressor front housing. The snap ring is located in a groove on the compressor shaft housing. Work carefully to avoid damaging the snap ring groove. Keep the snap ring in a safe place for reinstallation unless replacing.
4. 4

   Extract clutch coil assembly
   With the snap ring removed, carefully pull the clutch coil assembly straight off the compressor front housing. The coil should slide off with minimal resistance. If stuck, gently work it side to side while pulling. Do not pry against the compressor housing. Note the orientation and any shims for reassembly.
5. 5

   Inspect clutch components
   With the coil removed, inspect the clutch hub, pulley bearing, and compressor shaft for wear, scoring, or damage. Check the snap ring groove for damage. Verify the pulley rotates freely without wobble or noise. Clean any debris or metal shavings from the compressor face and coil mounting area with a wire brush.
6. 6

   Prepare new clutch coil
   Remove the new clutch coil from packaging and inspect for damage. Compare with old coil to verify correct replacement part. Check that the coil terminals are clean and undamaged. If any shims were present on the original coil, transfer them to the new coil in the same position.
7. 7

   Install new clutch coil
   Align the new clutch coil with the compressor housing, ensuring any alignment tabs or notches are properly positioned. Slide the coil straight onto the compressor housing until it seats fully against the mounting surface. The coil should fit snugly without forcing.
8. 8

   Reinstall snap ring
   Using snap ring pliers, carefully install the snap ring into its groove on the compressor housing. Ensure the snap ring is fully seated in the groove around its entire circumference. Verify the snap ring is secure and the clutch coil cannot move axially.
9. 9

   Verify clutch air gap
   Using a feeler gauge, check the air gap between the clutch hub and pulley at three points around the circumference. The gap should be 0.014-0.026 inches (0.36-0.66 mm). If gap is incorrect, add or remove shims between the coil and compressor housing. This ensures proper clutch engagement.
10. 10

    Reconnect electrical connector
    Push the electrical connector firmly onto the clutch coil terminals until it clicks into place. Verify the connector is fully seated and the retaining tab is engaged. Route the wiring to prevent contact with moving parts or hot surfaces.
11. 11

    Reinstall serpentine belt
    Route the serpentine belt according to the belt routing diagram on the fan shroud or under the hood. Rotate the belt tensioner clockwise and slip the belt onto the final pulley. Release tensioner slowly. Verify belt is properly seated on all pulleys including the AC compressor pulley.
12. 12

    Reinstall splash shield
    If the engine splash shield or skid plate was removed, reinstall it now using the original fasteners. Ensure all clips and bolts are secure.

Reassembly

1. Reconnect negative battery cable
2. Lower vehicle from jack stands
3. Double-check all fasteners and connections before starting engine

Verification

• Start engine and turn AC to maximum cooling with fan on high
• Listen for unusual noises from the compressor area during operation
• Verify the clutch engages smoothly when AC is turned on (pulley and hub should spin together)
• Verify clutch disengages when AC is turned off (only pulley spins, hub remains stationary)
• Check for proper cold air output from vents
• Inspect for any fluid leaks around compressor
• If available, use multimeter to verify clutch coil resistance is within specification (typically 3-5 ohms)

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