Replace the AC compressor clutch coil on a 2014 Ram 2500 with 6.7L Cummins diesel engine, requiring recovery and recharge of the AC system.

Warnings

Tools required

Parts

• AC compressor clutch coil × 1 — Use OEM Mopar specification
• AC clutch coil retaining snap ring × 1 — Often included with coil assembly
• PAG oil for AC system × 1 — Check compressor label for correct type

Preparation

1. Verify AC clutch coil failure by testing coil resistance (should be 3-5 ohms typically) and checking for visual damage
2. Park vehicle on level ground and apply parking brake
3. Allow engine to cool completely if recently operated
4. Disconnect negative battery cable to prevent accidental engagement
5. Recover all AC refrigerant using approved recovery equipment and record amount removed

Procedure

1. 1

   Access the AC compressor
   Remove the engine splash shield if equipped. The AC compressor is located on the passenger side of the engine, driven by the serpentine belt. You may need to remove the air intake or other components for better access depending on specific configuration.
2. 2

   Remove serpentine belt
   Using a breaker bar or serpentine belt tool, rotate the belt tensioner clockwise to release tension. Slide the serpentine belt off the AC compressor pulley and remove from engine. Inspect belt condition and replace if worn or damaged.
3. 3

   Disconnect clutch coil electrical connector
   Locate the electrical connector on the AC compressor clutch coil. Press the release tab and carefully disconnect the wiring harness from the coil. Inspect connector and pins for corrosion or damage.
4. 4

   Remove clutch coil retaining snap ring
   Using snap ring pliers or the clutch coil removal tool, carefully remove the snap ring that retains the clutch coil to the compressor front housing. Work the snap ring out of its groove, being careful not to damage the groove or allow the snap ring to spring away.
5. 5

   Extract the clutch coil
   Gently pull the clutch coil assembly straight out from the compressor housing. The coil should slide off the compressor shaft and bearing assembly. If resistance is felt, use a small pick to help separate any corrosion, but do not pry forcefully. Note the orientation and position of any shims behind the coil.
6. 6

   Clean mounting surfaces
   Thoroughly clean the compressor housing surface where the clutch coil mounts. Remove any dirt, debris, or corrosion using a clean shop towel. Inspect the clutch pulley bearing for smooth rotation and absence of noise. Check the clutch plate on the compressor shaft for wear or damage.
7. 7

   Install new clutch coil
   Install any shims that were present on the original coil in the same position. Carefully slide the new clutch coil onto the compressor housing, ensuring it seats fully against the mounting surface. The coil should slide on smoothly without binding. Align the electrical connector tab to the proper orientation.
8. 8

   Install retaining snap ring
   Install the new snap ring (or reuse if in good condition) into the groove on the compressor housing to secure the clutch coil. Ensure the snap ring is fully seated in its groove all the way around. Tug gently on the coil to verify it is properly retained.
9. 9

   Verify clutch air gap
   Using a feeler gauge, measure the air gap between the clutch plate and the pulley face at three points around the circumference. The gap should be 0.012-0.024 inches (0.30-0.61mm). If gap is incorrect, add or remove shims behind the clutch coil as needed. This is critical for proper clutch engagement.
10. 10

    Reconnect electrical connector and reinstall belt
    Reconnect the clutch coil electrical connector, ensuring it clicks into place securely. Route the serpentine belt back around all pulleys including the AC compressor pulley, following the belt routing diagram on the fan shroud. Rotate the tensioner and slip the belt into place.
11. 11

    Reconnect battery and test clutch operation
    Reconnect the negative battery cable. Before recharging the AC system, start the engine and turn on the AC to maximum. You should hear the clutch engage with a distinct click and see the clutch plate begin to rotate with the pulley. If no engagement occurs, recheck electrical connections and air gap.
12. 12

    Evacuate and recharge AC system
    Using proper AC service equipment, evacuate the system for at least 30 minutes to remove all air and moisture. Check for vacuum hold to verify system integrity. Recharge the system with the correct amount of R-134a refrigerant as specified on the underhood label (typically 2.6-3.0 lbs). Add appropriate amount of PAG oil if significant oil was lost during service.

Reassembly

1. Reinstall any components removed for access such as air intake or splash shields
2. Double-check all electrical connections are secure and properly routed
3. Verify serpentine belt is properly seated on all pulleys and tensioner is functioning correctly

Verification

• Start engine and turn AC to maximum cold with fan on high
• Verify clutch engages within 5-10 seconds with audible click and visual confirmation of clutch plate rotation
• Check that cold air is blowing from vents and temperature drops to approximately 40-45°F at the center vent
• Use refrigerant leak detector to check all connections and compressor for leaks
• Monitor system operation for 10-15 minutes to ensure clutch cycles properly and no unusual noises are present
• Verify no warning lights are illuminated on instrument cluster

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