2006 DODGE RAM SRT-10 clutch

INSTALLATION
DENSO A/C COMPRESSOR
NOTE: Typical A/C compressor shown in illustrations.
1. Align the dowel pin on the back of the compressor
clutch field coil (2) with the hole in the front of the
A/C compressor (3) and position the field coil onto
the compressor. Be certain that the compressor
clutch field coil wire lead is properly routed so that
it is not pinched between the A/C compressor and
the field coil.
CAUTION:Thesnapringmustbefullyandprop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.
NOTE:Anewsnapringmustbeusedtosecure
the compressor clutch field coil to the A/C com-
pressor. The bevel side of the snap ring must face
outward and both snap ring eyelets must be ori-
ented to the right or to the left of the field coil
dowel pin location on the A/C compressor.
2. Using snap ring pliers (Special Tool C-4574 or
equivalent) (1), install the snap ring (4) that
secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully
and properly seated in the groove and oriented correctly.
CAUTION:Becertaintopositionthecompressor
clutch field coil wire lead so that it is not damaged
during A/C compressor pulley and bearing instal-
lation.
CAUTION: When installing the pulley and bearing
assembly, DO NOT mar the friction surfaces of the
pulley or premature failure of the clutch will result.
3. Install the pulley and bearing assembly (1) onto the
front of the A/C compressor. If necessary, tap the
pulley gently with a block of wood (2) placed on the
pulley friction surface.

CAUTION:Thesnapringmustbefullyandprop-
erly seated in the groove or it will vibrate out,
resulting in a clutch failure and severe damage to
the A/C compressor.
NOTE:Anewsnapringmustbeusedtosecure
the pulley and bearing assembly to the A/C com-
pressor. The bevel side of the snap ring must face
outward.
4. Using snap ring pliers (2), install the snap ring (1)
that secures the pulley and bearing assembly (3) to
the front of the A/C compressor. Be certain that the
snap ring is fully and properly seated in the groove.
5. If the original clutch plate (2) and pulley and bear-
ing assembly are to be reused, reinstall the original
shim(s) (3) onto the compressor shaft (1). If a new
clutch plate and pulley and bearing assembly are
being used, install a trial stack of shims 2.54 mm
(0.010 in.) thick onto the compressor shaft.

6. Install the clutch plate (4) onto the front of the A/C
compressor (5).
7. Install the compressor shaft bolt (3). Tighten the
bolt to 19 Nꞏm (168 in. lbs.).
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is correct. Spin the pul-
ley before performing a final check of the air gap.
NOTE: On models with the clutch plate recessed
intothepulley,usea90°wiregapgaugetomea-
sure the clutch air gap. On other models, use a
blade type feeler gauge to measure the air gap.
8. With the clutch plate assembled tight against the
shim(s), measure the air gap between the clutch
plate and the pulley and bearing assembly. The air
gap should be between 0.35 - 0.60 mm (0.014 -
0.024 in.). If the air gap is not between specifica-
tions, add or subtract shims as needed until the
correct air gap is obtained.
CAUTION: Be certain that the compressor clutch field coil wire harness is properly routed so that it is not
pinched between the A/C compressor and the field coil connector bracket.
9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2).
10. Install the compressor clutch fieldcoil connector (1) onto the connector bracket.
11. Position the A/C compressor to the engine and install the retaining bolts (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/COMPRESSOR-A/C - INSTALLATION).
12. Connect the engine wire harness to the compressor clutch field coil connector.
13. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/BELTS-DRIVE - INSTALLATION).
14. Reconnect the negative battery cable.
VISTEON A/C COMPRESSOR
1. Position the A/C clutch field coil (1) squarely onto
the front of the A/C compressor (2).
CAUTION: Position the A/C clutch field coil so that
the coil positioning tabs and the wire harness lead
are oriented in the correct direction. Failure to cor-
rectly position the fieldcoil on the A/C compres-
sor will result in field coil damage.
2. Align the field coil positioning tabs to the recessed
area at the front of the A/C compressor and install
the clutch field coil onto the compressor using a
two jaw puller (3), compressor field coil installer
(Special Tool 9352 in Kit 9349) (4) and the com-
pressor field coil installer spacer (Special Tool 9353
in Kit 9349) (5).

3. Position the clutch fieldcoil wire lead and connec-
tor (3) to the A/C compressor (4) and install the
plastic retaining clip (1) and the screw (2) that
secures the wire lead to the compressor. Tighten
thescrewto4Nꞏm(35in.lbs.).
4. Align the pulley and bearing assembly (1) squarely
onto the front of the A/C compressor (2).
NOTE: A distinct change of sound during the
clutch pulley tapping process indicates that the
pulley and bearing assembly has bottomed out
against the compressor housing.
5. Using clutch pulley installer (Special Tool 9355 in
Kit 9349) (3) and a hammer (4), install the pulley
and bearing assembly onto the front of the A/C
compressor. Tap the installer with a hammer until
the pulley and bearing assembly has bottomed
against the compressor housing.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in clutch failure
and severe damage to the A/C compressor.
NOTE: Install the snap ring with the beveled side
ofthesnapringfacingoutward.
6. Using snap ring pliers (1), install the snap ring (2)
that secures the pulley and bearing assembly (3) to
the front of the A/C compressor (4). Make sure the
snap ring is properly seated in the groove.

7. Verify that there is adequate clearance for the
clutch field coil wire lead and connector (4)
between the compressor housing and the pulley.
NOTE: When installing an original or a new clutch
assembly, try the original shims first. When install-
ing a clutch onto a compressor that previously did
not have a clutch, use the 1.0, 0.50 and 0.13 milli-
meter (0.040, 0.020 and 0.005 inch) shims from the
clutch hardware package which is provided with
the new clutch.
8. Install the clutch shims onto the compressor shaft.
9. Using compressor clutch holding fixture (Special
Tool 9351 in Kit 9349) (1), install the bolt (2) that
secures the clutch plate (3) to the A/C compressor
(5). Hold the clutch plate stationary with the holding
fixture and tighten the bolt to 15 Nꞏm (133 in. lbs.).
10. Using a feeler gauge (1), check the air gap
between the clutch plate (2) and the pulley and
bearing assembly (3). If the air gap is not 0.35 to
0.75 millimeter (0.014 to 0.030 inch), add or sub-
tract shims as required.
11. Position the A/C compressor (4) onto the mount-
ing bracket.
12. Install the bolts that secure the A/C compressor to
themountingbracket.Tightentheboltsto23Nꞏm
(17 ft. lbs.).
13. Connect the engine wire harness to the compres-
sor clutch field coil connector (5).
14. Lower the vehicle.
15. Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
16. Reconnect the negative battery cable.
17. Perform the Clutch Break-in Procedure (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH - STANDARD PROCE-
DURE).

SENSOR-EVAPORATOR TEMPERATURE
DESCRIPTION
The evaporator temperature sensor is a two-wire tem-
perature sensing element located at the coldest point
on the face of the A/C evaporator. The probe (1) for
evaporator temperature sensor is attached to the
evaporator coil fins. The wire lead (2) for evaporator
temperature sensor is routed through an opening at
the back of the HVAC housing and the connector (3)
is attached to the HVAC wire harness.
OPERATION
The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal
to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize
A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sen-
sor will change its internal resistance in response to the temperatures itmonitors and is connected to the A/C-heater
control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator
decreases, the internal resistance of the evaporator temperature sensordecreases.
The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-
heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the
engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to
optimize A/C system performance and to protect the A/C system from evaporatorfreezing(Referto24-HEATING
& AIR CONDITIONING/CONTROLS/COIL-A/C COMPRESSOR CLUTCH - OPERATION formore information).
The evaporator temperature sensor is diagnosed using a scan tool (Refer to24 - HEATING & AIR CONDITIONING
- DIAGNOSIS AND TESTING and to 24 - HVAC Electrical Diagnostics for more information).
The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.

TRANSDUCER-A/C PRESSURE
DESCRIPTION
The A/C pressure transducer (1) is a switch that is
installed on a fitting located on the A/C discharge line.
An internally threaded fitting on the A/C pressure
transducer connects it to the externally threaded
Schrader-type fitting on the A/C discharge line. A rub-
ber O-ring seals the connection between the A/C pres-
sure transducer and the discharge line fitting. The A/C
pressure transducer is connected to the vehicle elec-
trical system by a molded plastic connector with three
terminals.
OPERATION
The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection
to a fitting on the A/C discharge line. The A/C pressure transducer will change its internal resistance in response to
the pressures it monitors. A Schrader-type valve in the A/C discharge linefitting permits the A/C pressure transducer
to be removed or installed without disturbing the refrigerant in the A/C system.
The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. The pow-
ertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five
volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the
transducer on a sensor return circuit to determine refrigerant pressure.The PCM/ECM is programmed to respond to
this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan
to help optimize A/C system performance and to protect the system components from damage. The PCM will dis-
engagetheA/Ccompressorclutchwhenhighsidepressurerisesabove3172kPa (460 psi) and re-engage the
clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage
the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch
when the high side pressure rises above 234 kPa (34 psi). If the refrigerantpressure rises above 1655 kPa (240
psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM will also prevent the
A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pres-
sure/temperature relationship of the refrigerant. The A/C pressure transducer input to the PCM/ECM will also pre-
vent the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to
the pressure/temperature relationship of the refrigerant.
The A/C pressure transducer is diagnosed using a scan tool. Refer to 9 - Engine Electrical Diagnostics for more
information.
The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.
REMOVAL
NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer.

degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and
turn off vacuum pump. If the system failsto reach specified vacuum, the refrigerant system likely has a leak that
must be corrected. If the refrigerantsystem maintains specified vacuum for at least 30 minutes, start the vacuum
pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes.
4. Close all valves. Turn off and disconnect the vacuum pump.
5. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
REFRIGERANT SYSTEM CHARGE
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
NOTE: Always refer to the Underhood HVAC Specification Label for the refrigerant fill specification of the
vehicle being serviced.
After all refrigerant system leaks have been repaired and the refrigerantsystem has been evacuated, a refrigerant
charge can be injected into the system. For the proper amount of the refrigerant charge, refer to the Underhood
HVAC Specification Label.
An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge
the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment man-
ufacturer for proper care and use of this equipment.
CHARGING PROCEDURE
CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant sys-
tem is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during
the recovery process. Refer the equipment manufacturer instructions formore information.
1. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE).
2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard
J2210 should be connected to the refrigerant system.
3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) withthe charging station. See the oper-
ating instructions supplied by the equipment manufacturer for proper useof this equipment.
4. Open both the suction and discharge valves, then open the charge valve toallow the heated refrigerant to flow
into the system.
5. When the transfer of refrigerant has stopped, close both the suction anddischarge valves.
6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle
and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is oper-
ating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor
does not engage, test the compressor clutch control circuit and repair as required.
7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system.
WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this
warning could result in possible personal injury or death.
8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports.
9. Reinstall the caps onto the refrigerant system service ports.