This procedure covers the replacement of the AC compressor clutch assembly on a 2015-2020 Ford F-150 with 5.0L V8 engine, including refrigerant recovery, clutch removal, and system recharge.

Warnings

Tools required

Parts

• AC compressor clutch assembly × 1 — Use OEM specification
• AC line O-rings × 1 — Use OEM specification
• Refrigerant R-134a × 1 — As required by system capacity
• PAG 46 compressor oil × 1 — Use OEM specification

Fluids

• PAG 46 AC compressor oil — 0.25 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery terminal and wait 2 minutes
4. Raise front of vehicle and support on jack stands at frame rails
5. Remove engine undershield/splash guard to access compressor from below

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to service ports. Follow machine instructions to fully recover all refrigerant from the system. Record the amount recovered for reference during recharge. Allow system to stabilize and verify complete recovery.
   ⚠️Never vent refrigerant to atmosphere. Use certified recovery equipment only.
2. 2

   Disconnect AC line fittings
   Locate the AC line connections at the compressor. Remove the spring-lock couplings or bolted fittings using appropriate disconnect tools. Cap all open ports immediately to prevent contamination. Inspect O-rings and discard. Drain and measure any oil that escapes from lines.
   ⚠Cap all openings immediately to prevent moisture contamination of AC system.
3. 3

   Remove serpentine belt
   Locate the belt tensioner on the front of the engine. Using a 3/8 inch breaker bar, rotate the tensioner clockwise to relieve tension. Slide the serpentine belt off the AC compressor pulley, then release tensioner and remove belt completely. Note belt routing for reinstallation.
4. 4

   Disconnect compressor electrical connector
   Locate the electrical connector on the AC compressor clutch coil. Press the release tab and disconnect the connector. Move wiring harness aside to prevent damage during clutch removal.
5. 5

   Remove clutch retaining bolt
   Using the clutch holding tool to prevent pulley rotation, remove the center bolt securing the clutch assembly to the compressor shaft. This bolt has standard right-hand threads. Remove the bolt and any washers present.
   ⚠Do not allow compressor shaft to rotate during bolt removal to prevent internal damage.
6. 6

   Remove clutch retaining snap ring
   Using snap ring pliers, carefully remove the snap ring from the groove on the compressor shaft. Take care not to distort the snap ring excessively. Inspect snap ring for damage and replace if worn or deformed.
7. 7

   Remove clutch plate and pulley assembly
   Pull the clutch plate straight off the compressor shaft. It may require gentle prying with two small pry bars positioned opposite each other. Next, remove the pulley assembly with bearing from the compressor nose. Inspect the bearing for roughness or noise.
8. 8

   Remove electromagnetic coil
   Remove the retaining ring or bolts securing the electromagnetic coil to the compressor housing. Carefully slide the coil assembly off the compressor nose. Inspect the coil for burns, cracks, or damage.
9. 9

   Install new electromagnetic coil
   Slide the new electromagnetic coil onto the compressor nose, ensuring proper alignment. Secure with retaining ring or bolts as per original configuration. Verify coil is fully seated against compressor housing.
10. 10

    Install new pulley and clutch plate
    Install the new pulley/bearing assembly onto the compressor nose. Install the new clutch plate onto the compressor shaft, ensuring the friction surface faces the pulley. Install the snap ring into the shaft groove using snap ring pliers, ensuring it is fully seated.
11. 11

    Install and torque clutch bolt
    Install the center retaining bolt with washer. Using the clutch holding tool to prevent rotation, torque the bolt to manufacturer specification (typically 18-25 ft-lbs, though not specified in available data). Verify clutch plate does not bind on pulley.
12. 12

    Set clutch air gap
    Using a feeler gauge, measure the air gap between the clutch plate and pulley at multiple points around the circumference. The gap should be 0.014-0.022 inches (0.35-0.55mm). Add or remove shims behind the clutch plate as needed to achieve proper gap. This is critical for proper clutch engagement.
    ⚠Incorrect air gap will cause clutch failure. Verify gap at 3-4 points around circumference.
13. 13

    Reconnect electrical connector and reinstall belt
    Reconnect the electrical connector to the compressor clutch coil, ensuring it clicks into place. Reinstall the serpentine belt following the correct routing diagram (typically found on radiator core support). Use tensioner to slip belt onto all pulleys.
14. 14

    Reconnect AC lines
    Install new O-rings on all AC line fittings, lubricating with PAG oil. Reconnect AC lines to compressor and tighten fittings. Torque spring-lock or threaded fittings to specification.
    Torque spec

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

    Evacuate and recharge system
    Connect evacuation equipment and pull vacuum on system for minimum 30 minutes. System should hold vacuum without rising pressure. Add the measured amount of PAG oil that was lost during disassembly plus 1 oz for new clutch. Recharge system with proper amount of R-134a refrigerant per underhood specifications.

Reassembly

1. Reinstall engine undershield/splash guard
2. Lower vehicle from jack stands
3. Reconnect negative battery terminal
4. Start engine and verify belt tracking is correct on all pulleys

Verification

• With engine running, turn AC on maximum cold and high blower speed
• Verify compressor clutch engages with audible click and pulley/clutch spin together
• Check for abnormal noise from compressor or pulley bearing
• Monitor AC line temperatures - suction line should be cold, discharge line hot
• Verify vent temperature reaches below 50°F within several minutes
• Inspect all AC line connections for leaks using leak detector or soap solution
• Verify clutch disengages when AC is turned off and only pulley continues spinning
• Test clutch cycling under various load conditions to ensure proper operation

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