This procedure covers the removal and replacement of the AC compressor clutch assembly on a 2015-2020 Ford F-150 with the 3.5L EcoBoost engine, including refrigerant recovery, clutch replacement, and system recharge.

Warnings

Tools required

Parts

• AC compressor clutch assembly × 1 — Use OEM specification
• AC line O-rings × 4 — Use OEM specification
• PAG oil (for compressor) × 1 — Motorcraft PAG-46
• R-134a refrigerant × 1 — As required by recovery machine
• Serpentine belt (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Raise and secure front of vehicle on jack stands at manufacturer-specified lift points
4. Remove passenger side front wheel for improved access
5. Remove engine splash shield and passenger side fender liner panels
6. Disconnect negative battery cable and wait 2 minutes
7. Have AC system professionally evacuated and refrigerant recovered, noting the amount removed for recharge

Procedure

1. 1

   Remove serpentine belt
   Locate the automatic belt tensioner on the front of the engine. Using a 3/8-inch ratchet or belt tensioner tool, rotate the tensioner clockwise to release tension. Slide the serpentine belt off the AC compressor pulley first, then remove from remaining pulleys. Inspect belt for wear, cracks, or glazing and replace if necessary. Note belt routing for reinstallation.
2. 2

   Disconnect AC line fittings
   Locate the AC line connections on the rear of the compressor. Using appropriate wrenches, disconnect both the high-pressure (smaller) and low-pressure (larger) AC line fittings from the compressor. Immediately cap all openings with plastic caps to prevent moisture and contamination from entering the system. Remove and discard the old O-rings from the line fittings.
   ⚠Even after recovery, residual refrigerant and oil may be present. Work in a well-ventilated area and wear safety glasses.
3. 3

   Disconnect clutch electrical connector
   Locate the AC clutch field coil electrical connector on the front of the compressor. Press the locking tab and disconnect the connector. Move the wiring harness aside to provide clearance for clutch removal.
4. 4

   Remove clutch hub snap ring
   Using internal snap ring pliers, carefully remove the snap ring that retains the clutch hub to the compressor shaft. The snap ring is located in a groove on the compressor shaft just behind the clutch hub. Keep the snap ring in a clean location for reinstallation or replacement.
5. 5

   Remove clutch hub assembly
   Install the clutch hub removal tool onto the clutch hub. The hub is pressed onto the compressor shaft with a friction fit. Thread the removal tool until the clutch hub releases from the shaft. Remove the hub assembly and inspect the shaft for damage, scoring, or corrosion. Clean the shaft with a wire brush if necessary.
   ⚠Do not use a gear puller or improvised tools that could damage the compressor shaft or internal bearings.
6. 6

   Remove clutch pulley snap ring
   Locate the external snap ring that retains the pulley bearing assembly to the compressor nose. Using snap ring pliers, carefully remove this snap ring. Be cautious as the pulley is under slight spring pressure from the shim pack.
7. 7

   Remove pulley and bearing assembly
   Carefully pull the pulley and bearing assembly straight off the compressor nose. Note the position and quantity of any shims behind the pulley, as these control clutch air gap. Keep shims organized for reinstallation. Inspect the pulley bearing for smooth rotation and absence of noise or roughness.
8. 8

   Remove field coil assembly
   Locate the retaining screws or snap ring that secures the field coil (electromagnetic coil) to the compressor nose. Remove the fasteners and carefully extract the field coil assembly, feeding the wire connector through the compressor housing. Inspect the coil for burns, cracks, or damage.
9. 9

   Install new field coil
   Install the new field coil assembly onto the compressor nose, routing the electrical connector through the housing opening. Ensure the coil seats fully and flat against the compressor nose. Secure with the retaining hardware. If reusing the original coil and it tests good, clean the contact surfaces and reinstall.
10. 10

    Install pulley and bearing assembly
    Install the original shim pack onto the compressor nose. Place the pulley and bearing assembly over the nose, ensuring it slides on smoothly. Install the external snap ring to retain the pulley. Verify the pulley rotates freely without binding or excessive play.
11. 11

    Install new clutch hub
    Align the new clutch hub onto the compressor shaft, ensuring the keyway or alignment feature is properly positioned. Press or tap the hub onto the shaft until it is fully seated. The hub should slide on with moderate resistance. Install the snap ring into the shaft groove to retain the hub. Verify the snap ring is fully seated in the groove.
12. 12

    Check and adjust clutch air gap
    Using a feeler gauge, measure the air gap between the clutch hub face and the pulley face at three points around the circumference (120 degrees apart). The gap should be 0.014-0.026 inches (0.36-0.66 mm). If adjustment is needed, remove the pulley snap ring and add or remove shims from behind the pulley. Recheck gap after any shim changes.
    ℹ️Incorrect air gap will cause clutch slippage (too large) or constant engagement and premature wear (too small).
13. 13

    Reconnect clutch electrical connector
    Reconnect the field coil electrical connector, ensuring it clicks into place securely. Optionally, test clutch operation before installing AC lines by temporarily reconnecting the battery and activating the AC system to verify the clutch engages with an audible click.
14. 14

    Install AC line fittings with new O-rings
    Install new O-rings onto the AC line fittings, coating them lightly with clean PAG-46 oil. Connect both the high-pressure and low-pressure lines to the compressor. Hand-tighten the fittings first, then torque to specification using a backup wrench on the compressor port to prevent rotation.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
15. 15

    Reinstall serpentine belt
    Route the serpentine belt around all pulleys following the routing diagram (typically shown on a decal under the hood or in owner's manual). Use the belt tensioner tool to rotate the tensioner clockwise and slip the belt onto the final pulley. Release the tensioner slowly and verify proper belt seating on all pulleys.

Reassembly

1. Reinstall passenger side fender liner panels and engine splash shield
2. Reinstall passenger side front wheel and torque lug nuts to specification (150 lb-ft for F-150)
3. Lower vehicle from jack stands
4. Reconnect negative battery cable

Verification

• Have AC system evacuated and recharged to proper refrigerant capacity using recovery/recharge machine
• Start engine and turn AC to maximum cold with blower on high
• Verify clutch engages with an audible click when AC is activated and disengages when turned off
• Check for cold air from vents within 1-2 minutes of operation
• Inspect all AC line connections for leaks using electronic leak detector or soap solution
• Verify clutch does not slip under load by monitoring engine RPM change when clutch engages
• Listen for unusual noises from compressor area during operation
• Confirm proper belt tension and alignment after test drive

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