1999 DODGE RAM clutch

5) Remove clutch coil wire harness retainer from compressor
housing. Remove clutch coil snap ring and clutch coil.
Installation (Ford "F" Series Super Duty Pickup)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub.
2) Install pulley installer handle and driver into pulley
assembly bearing cavity. Ensure outer edge of driver rests firmly on
inner race of bearing. Using hammer, install pulley and bearing
assembly. While tapping on handle, guide pulley and bearing assembly
to prevent binding. Ensure pulley assembly bottoms against compressor
housing.
3) Install internal bearing and external front housing snap
rings. Install original shim(s) and compressor shaft key. Using a
hammer and shaft protector, install clutch plate on compressor shaft.
Ensure clutch plate bottoms out on clutch shims. Replace compressor
shaft nut and tighten compressor shaft nut to 25-30 ft. lbs. (34-41 N.
m).
4) Measure air gap between clutch plate and pulley assembly
in 3 locations spaced equally around pulley. Rotate clutch pulley 180
degrees and check air gap as specified. Air gap should be 0.016-0.031"
(0.41-0.79 mm). If air gap is not within specification, adjust shim
thickness as necessary. To complete installation, reverse removal
procedure. Evacuate, charge, and leak test A/C system.
SANDEN TRS-90 & TR-105 SCROLL
CLUTCH ASSEMBLY
Removal
1) Without discharging A/C system, remove compressor from
mount. Install two 6-mm bolts in holes of clutch plate. Use 6-mm bolts
and 2 box-end wrenches to hold clutch plate while removing nut from
end of compressor shaft.
2) Remove clutch plate and shims. Using a plastic hammer, tap
clutch plate to loosen from compressor (if necessary). DO NOT pry
between clutch plate and pulley to remove clutch plate.
3) Remove pulley assembly snap ring. Remove pulley assembly.
Disconnect clutch coil lead. Scribe marks on clutch coil and
compressor for installation reference. Remove snap ring and clutch
coil.
NOTE: Rotor/pulley assembly and clutch plate are a matched pair and
should be replaced together.
Installation
1) Install clutch coil on compressor so locating pin engages
locating indentation. Install snap ring with beveled side away from
compressor. Secure clutch coil lead to compressor front cover and
connect lead to thermal limiter switch.
2) Install pulley assembly. Install snap ring with beveled
side away from compressor. If reusing original clutch plate and
pulley, old shims can be used.
3) If new components are used, install several shims so shim
pack thickness is 0.10" (2.5 mm). Align machined match marks and
install clutch plate and hold it tightly against shims.
4) Measure air gap between clutch plate and pulley surface.
Air gap should be 0.013-0.025" (0.33-0.64 mm). Adjust shim thickness
as necessary. On TRS-90, tighten compressor shaft nut to 13 ft. lbs.
(18 N.m). On TR-105, tighten compressor shaft nut to 10 ft. lbs. (14
N.m).

5) Once compressor shaft nut is tightened, check air gap
between clutch plate and pulley surface in at least 4 places. Readjust
air gap if necessary. Install A/C compressor. Evacuate and charge
system. Perform leak test. Ensure A/C system is operating properly.
6) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
SHAFT SEAL
Shaft seal is not serviceable. If excessive oil is present on
pulley and plate friction surfaces or on compressor shaft nose area,
replace compressor.
ZEXEL ROTARY VANE
CLUTCH ASSEMBLY
NOTE: Discharging A/C system and removing refrigerant lines from
compressor is not necessary to service clutch assembly.
Removal
1) Loosen tensioner and remove drive belt from pulley.
Disconnect clutch electrical connector. Remove compressor mounting
bolts. With refrigerant lines connected lift compressor upward and
forward. Install one front mounting bolt through bottom rear
compressor mounting ear. Tighten bolt so compressor is supported by
mounting bracket.
2) Using Clutch Drive Plate Holder (SA9510AC), remove clutch\
drive plate center bolt. Insert Clutch Drive Plate Remover Sleeve
(SA9506AC) into center of drive plate. Install remover bolt. While
holding clutch remover sleeve, tighten remover bolt and remove drive
plate and shims.
3) Remove pulley external snap ring. Position Puller Center
Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller\
to back of pulley. Tighten puller bolt against pulley center adapter
and remove pulley. Remove clutch coil screws. Disconnect clutch coil
wire. Remove clutch coil.
Installation
1) Install coil in original position. Ensure electrical
connector is aligned with indent in front of compressor head. Tighten
screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC\
-
3) and thrust bearing on installation bolt and insert through center
of pulley. Finger-tighten pulley installation bolt into compressor
shaft.
2) Finger-tighten nut on installation bolt to align pulley to
compressor. Hold end of bolt and tighten nut until pulley bottoms on
compressor. Loosen nut and remove installation bolt, thrust bearing
and drive plate installer. Install snap ring with tapered side out.
3) Install thrust bearing on installation bolt and insert
through clutch drive plate. Place original shims on installation bolt.
Thread bolt into compressor shaft. Hold end of bolt and tighten nut
until clutch drive plate bottoms out. Loosen nut and remove
installation bolt and thrust bearing. Install center bolt and tighten
to 115 INCH lbs. (13 N.m) using clutch drive plate holder.
4) Using a feeler gauge, measure air gap between drive plate
and pulley. Air gap should be 0.018-0.030" (0.46-0.76 mm). If air gap
is not as specified, add or remove shims as necessary. Install
compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs.


A/C -H EA TE R S YSTE M T R O UBLE S H O OTIN G

1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
Trouble Shooting - Cars & Trucks
CHRYSLER
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van/Wagon, Sebring Convertible,
Sebring Coupe, Stratus, Town & Country, Voyager, 300M
A/C SYSTEM DIAGNOSIS
RAPID COMPRESSOR CLUTCH CYCLING
Some possible causes of rapid compressor clutch cycling,
clutch cycles 10 or more times per minute, include:
* Low refrigerant system charge.
* Faulty low pressure cycling clutch switch.
* Faulty PCM.
COMPRESSOR WILL NOT ENGAGE
Some possible causes of compressor not engaging with high and
low side system pressures equal include:
* No refrigerant in system.
* Faulty fuse.
* Faulty compressor clutch coil.
* Faulty compressor clutch relay.
* Faulty electronic cycling clutch switch.
* Improperly installed or faulty low pressure cycling clutch
switch.
* Faulty low pressure cut-off switch.
* Faulty high pressure cut-off switch.
* Faulty PCM.
* Faulty A/C-heater control panel.
TEMPERATURE IS TOO HIGH WITH A/C ON
Some possible causes of high temperature output at center
panel when A/C system pressure is normal include:
* Excessive oil charge in refrigerant.
* Temperature control cable improperly installed or faulty.
* Blend-air door inoperative, obstructed or sealing
improperly.
* Blend door actuator not calibrated.
LOW SIDE PRESSURE IS LOW-TO-NORMAL & HIGH SIDE PRESSURE IS
LOW
Some possible causes of low side system pressure being lower-
to-normal and high side system pressure being too low include:
* Low refrigerant system charge.
* Refrigerant flow through accumulator is restricted.
* Refrigerant flow through evaporator is restricted.
* Faulty compressor.
LOW SIDE PRESSURE IS HIGH-TO-NORMAL & HIGH SIDE PRESSURE IS

Fig. 5: A/C Compressor & Compressor Clutch Diagnosis (1 Of 2)
Courtesy of Chrysler Corp.

Fig. 6: A/C Compressor & Compressor Clutch Diagnosis (2 Of 2)
Courtesy of Chrysler Corp.


* A /C -H EA TE R S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
A/C-Heater System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Heating, Ventilation and Air Conditioning
ACCUMULATORS
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AIR CONDITIONING FITTINGS
AIR CONDITIONING HOSES
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONTROL DOORS
AIR DAMS (EXTERNAL)
AIR DISTRIBUTION SYSTEM
BELTS
BLEND DOORS
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER MOTORS
BLOWER RESISTORS
BLOWER SWITCHES
CABIN AIR FILTERS
CIRCUIT BREAKERS
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSORS
CONDENSER AIR SEALS
CONDENSER FAN MOTORS
CONDENSERS
CONNECTORS
CONTROL CABLES
CONTROL HEADS (FUNCTION SELECTORS)
CONTROL LINKAGES
CONTROL MODULES
COOLANT
COOLING FAN BLADES
COOLING FAN CLUTCHES
COOLING FAN MOTORS
EVAPORATOR DRAIN TUBES
EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATORS
EXPANSION VALVES
FUNCTION SELECTORS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GASKETS
HEATER CASES
HEATER CONTROL VALVES
HEATER CORES

Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ (2) Require replacement.
Insulation overheated ... A ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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BLOWER SWITCHES
See SWITCHES.
CABIN AIR FILTERS
CABIN AIR FILTER INSPECTION








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Condition Code Procedure
Air flow obstruction .... A ............. Require cleaning or
replacement.
Maintenance intervals ... 3 ............ Suggest replacement.
Missing ................. C ............ Require replacement.









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CIRCUIT BREAKERS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSOR CLUTCH ASSEMBLY INSPECTION








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Condition Code Procedure
Air gap incorrect ....... B .. Require repair or replacement.
Bearing seized .......... A .. Require replacement of bearing
or assembly.
Bearing worn, affecting
performance ............ A .. Require replacement of bearing
or assembly.
Coil shows signs of
overheating ............ 1 .... Suggest replacement of coil.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,

Bent .................... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.









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COOLING FAN CLUTCHES
NOTE: Some lateral movement, measured at the fan blade tip, may
be normal.
COOLING FAN CLUTCH INSPECTION









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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bearing noisy ........... A ............ Require replacement.
Bearing worn ............ A ............ Require replacement.
Fastener loose .......... A ... Require repair or replacement
of fastener.
Inoperative ............. A ........ ( 1) Require replacement.
Leaking ................. 1 ............ Suggest replacement.
Seized .................. A ............ Require replacement.
Slips (insufficient fan
speed) ................. A ............ Require replacement.
Thermal control
incorrect .............. B .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.









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COOLING FAN MOTORS
COOLING FAN MOTOR INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... ( 1) Require repair or
replacement.