A/C Compressor replacement??

[Arkmx]

Ford dealer says my compressor is locked up and that is what is causing my truck not to start (turns over but sluggish). I swapped out the batteries and replaced the starter with the same results. it was towed to the dealer today and they want a $2000 bill to replace the compressor etc., a tensioner & the drive belt. Ouch...

Seems odd that the A/c comp., could drag down the motor so much that it would not let the engine start....

Well has anyone changed out the A/C compressor? The book says 7.4 hours... Is this something a mechanically inclined person could do them selves? Are any special tools needed to do the job? Anyone have or know of a link to doing the job?

Need to get it running again so we can get to the races.....

Thanks in advance!
Jim.

2003 F250, 6.0 with 188,000 miles, 2wd, auto.

[tech10002]

It seems strange that the compressor would be locked and the compressor clutch would also be seized. Have you tried starting the truck with the A/C switch turned off?

If the problem is indeed the compressor/clutch and there is no other damage, like debris in the condenser from the compressor being broken up inside, it's a pretty easy swap. You'll need to change the compressor and clutch as an assembly, accumulator/drier, and orifice tube. You'll need some PAG refrigeration oil to lube the o-rings when you put it back together, refrigerant, gauges, and a vacuum pump. Assuming you can borrow the pump and gauges from somebody, you're probably looking at $400-500 worth of parts depending on what you can get the compressor for. If the condenser is full of garbage, then figure another few hours to flush it out. Make sure you flush the high pressure line leading from the compressor to the condenser and the liquid line from the condenser to the orifice tube too. They sell the flush fluid at any auto parts store. You just pour it in and blow it through with air. If it's really bad, you might need to change the condenser. That's as far as the damage is likely to go, though. The orifice tube has a screen in it and will catch the garbage before it hurts the evaporator or lines leading from it. When you remove the orifice tube, check it for chunks of metal or metal shavings. That will give you a pretty good idea if you have garbage in the condenser too.

Once you get everything changed, you need to evacuate the system to a 30" vacuum for at least a couple hours and then charge it.

It's not that tough, but you might want to see if you have any buddies with HVAC experience. It will be a lot easier then.

[Arkmx]

Tech.... Thanks for the info! I 99.9% of the time do not start the truck with the AC switch in the on position. I like to have all the extra stuff off when I shut the engine off, except for the radio.

I found a A/C comp., kit with at NAPA for $260, pretty good deal since Ford wants $303 just for the comp.

Thanks again!
Jim.

[tech10002]

You don't have to shut off the A/C switch when you turn the truck off if you don't want to. It is never engaged until after the truck starts if it's working properly.

Just to be sure it's the compressor, take the belt off and then try spinning it by hand with the key off. If the clutch is good, it should just spin free and the compressor itself will not turn. If the clutch itself is bad and the compressor is okay, it will spin over with a little resistance. If it's very hard to turn or seized all together, then you'll definitely need to replace it.

Make sure that kit comes with both the compressor and clutch. Some times they're sold separately, and setting them up can be a bit of a pain if they're not already assembled. You have to shim them to a certain clearance. Also, make absolutely sure the compressor is filled with PAG oil designed for 134a. If you're not sure, turn the new one upside down, drain out the oil, and replace it with the same volume of PAG oil. The oil type is usually indicated on the box or on a sticker affixed to the compressor.

Also, make sure you at least change the accumulator and orifice tube and check for debris in the orifice screen. Those are steps you absolutely should not skip.

[rophoo1]

Anyone know of a belt to do away with the ac compressor or how to change it?

[dhanna6powerstroke]

You can regap the clutch and see if that fixes your problem. Seems to be pretty common on the 6.0 and I think there is a write up on here somewhere.