Kevinlow831
New Member
- Joined
- April 16, 2025
- Messages
- 7
- Reaction score
- 1
- City, State
- Lake Wales
- Year, Model & Trim Level
- 2011 Explorer Limited
Hi. I thought I would post this as a help to anyone who may have AC inop due to compressor clutch failure.
My 2011 Limited 3.5 AC suddenly stopped working. Hot day 98 Degrees. No warning just suddenly hot air.
When I got home I sat down to diagnoses.
I have Forscan so plugged in read codes (Nothing stored that was relevant)
Read data for compressor to see that the car was trying to engage the compressor when the AC button in the cabin was pressed.
There was no click from the compressor, AC did not kick in.
Next, I checked the voltage at the plug to the AC clutch coil pack. This did produce 12V (13.6V while engine running) when AC button was pressed and went to zero when AC button was switched off.
So simple diagnosis was a failed AC clutch coil.
This looked fairly simple to replace although not much room. So ordered a 3 piece kit. Coild, pulley and clutch
Here is my repair procedure which I did at home with the car on the ground. No Ramp or special tools
Hope this helps any of you wondering if this can be done without removing the compressor.
My 2011 Limited 3.5 AC suddenly stopped working. Hot day 98 Degrees. No warning just suddenly hot air.
When I got home I sat down to diagnoses.
I have Forscan so plugged in read codes (Nothing stored that was relevant)
Read data for compressor to see that the car was trying to engage the compressor when the AC button in the cabin was pressed.
There was no click from the compressor, AC did not kick in.
Next, I checked the voltage at the plug to the AC clutch coil pack. This did produce 12V (13.6V while engine running) when AC button was pressed and went to zero when AC button was switched off.
So simple diagnosis was a failed AC clutch coil.
This looked fairly simple to replace although not much room. So ordered a 3 piece kit. Coild, pulley and clutch
Here is my repair procedure which I did at home with the car on the ground. No Ramp or special tools
- I raised the car on a stand on the passenger side enough to get underneath the front.
- I removed the front end of the wing/fender liner and peeled back wedging it against the tire to keep it back. You can then see the compressor clutch
- Laying underneath long ways, head in the wheel arch up against the tire (painful but the only way I could see what I was doing)
- I wedged the compressor clutch (6 oclock position) with a screwdriver into a gap in next to the radiator which held it tight while I cracked off the 10mm bolt. tight but undone with a 1/4" ratchet and some extensions
- I pulled off clutch and retrieved loose shims from inside and put the shims aside for later
- Next bit a little fiddly. I sprayed the circlip with WD40 (or similar) left for a few mins. Used 90 degree circlip pliers to remove the external circlip holding on the pulley.
- Pulley will not come off easily. I did not see a way to get a puller in front and also do not have one so gently tapped the inside (side nearest engine) of the pulley while rotating it to free it off. DO NOT hit it hard as you may dent it or crack it. But firm taps are enough to free it and eventually it will start to move. I continued to tap it until it came off the shaft. (I was replacing this in a kit with a coil, pulley and clutch so was not bothered about damage. I did not damage it getting it off though)
- Next, even more fiddly. The Coil is held on by another external circlip which is recessed about 1.5 inches. Again give it a spray of WD40 and leave for a few mins. I had a set of circlip pliers that were right angle to the handle so was able to get these in. You cannot see what you are doing at this point and feel is the only way. Much fiddling and trying the clip sprung free.
- Now the original coil wire is held on by a screw clip into the top of the compressor. You cannot get to this unless the compressor is removed. As I was replacing the coil pack I cut the wire and pulled it through the clip. My intension was to cable tie the wire back in place
- Next, undo the connector from the coil pack to the harness in front of the compressor
- The coil just pulls off but note it has a locating peg on the back.
- Coil pack is located in one position and is held on with a new circlip. Hold in position and put in circlip. Gently tap the cir clip to make sure it home correctly and the coild pack will not rotate and is firm in position
- The wire I tied wrapped in 2 places to stop it coming in contact with the new pulley
- Plugged coil pack back in to connector
- Put on new pulley. this needed tapping on. I used a wooded drift and hammer just to tap it home while rotating it. I it secured with a new circlip, fairly easy to do, but again give it a tap to make sure it home fully and pulley feels secure, runs true.
- Put on new clutch pack and air gapped to 0.5mm. (I had to use extra shims along with the original one to gap correctly, this could be down to part design). Used a screwdriver again to wedge the clutch pack in the opposite direction, 12 o'clock position this time. Tighten 10mm bolt
- Check the clutch and pulley spin independently.
- Refit wing/fender liner.
- Lower car to the ground
- Start engine,
- AC on, wait for click
- Cool air again!!!!
Hope this helps any of you wondering if this can be done without removing the compressor.
