Expert: Roland Finston - 12/15/2011

Question
2002 Town and Country  It looks like there was a rubber bushing between pulley and outer clutch plate, hence the plate which seems to be somewhat magnetic rattles when the engine is running.  Tried to remove 10mm center bolt and pry off, but not coming easily.  What's the next step?  Thanks, Mike

Answer
Hi Mike,
The '98 manual is the closest to the '02 which shows the dismantling of the compressor clutch.
To remove the center bolt it suggests using an oil filter band type of 'wrench' around the clutch plate circumference.
Don't use screwdrivers between the clutch plate assembly and pulley to remove the front plate as this may damage the front plate.
Tap the clutch plate with a plastic hammer and remove the clutch plate and small shim(s).
Remove pulley retaining snap ring with snap-ring pliers and slide pulley assembly off of compressor. Remove coil wire clip screw and wire harness. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing
Examine frictional faces of the clutch pulley and front plate for wear. They should be replaced if there is excessive wear or scorching. If the face are oily inspect the shaft nose area of the compressor and remove the felt from the front cover. If the compressor felt is saturated with oil, shaft seal is leaking and will have to be replaced.
Check bearing for roughness, excessive leakage, or grease. If grease has contaminated the surfaces of the pulley or front plate, they should be replaced. If the bearing is rough or binds, replace the clutch pulley and front plate assembly.  Always replace them as a pair. There is an 8-step installation procedure I can share with you when you are ready for that.
Roland
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