2001 Pontiac Bonneville A/C Clutch

[dougtoth]

Another question about my 2001 SLE.
The clutch on my A/C compressor is making noise when the A/C is turned off.
The compressor is fine and the air is cool.
Can you just replace the clutch?
Also can you do this without taking the unit out and disconnecting the hoses?
It looks like there is a nut in the middle of the clutch that you take off.

Thank you.

[MKMike]

Yes, you can replace the clutch plate alone but you might be able to just evenly pry it away from the pulley to stop the grinding.
This seems to be a rather common problem; likely due to the metal fatiguing over time, so it doesn't spring back enough when the clutch is supposed to disengage.
Replacing the clutch plate requires a few special tools--borrowable from some parts stores.
It doesn't just come off when you remove the nut.

Youtube has some decent videos about V5 and V7 compressors
This is one of the better ones https://www.youtube.com/watch?v=dsacpKR_sA8
At around 6 minutes, you'll see the special tool needed to remove the clutch plate, after the nut was removed.

Here's an excellent GM document with illustrations of the compressors that our cars use.
http://www.gmforum.com/howto/1998SM/ac% ... vicing.pdf

[dougtoth]

Thanks MKMike.
I did not realize that it was that involved.
In other words is it the bearing that has gone bad and causing the grinding noise?
From what I can see it does not want to spring back when disengaged.
I can see metal flakes besides hearing the grinding noise.
Is it possible to drop the unit without disconnecting the hoses and still have room to work on the unit.
I watched both parts of the video and he was working on a Chevrolet Prism which had plenty of room.
It also looks like I will need a special puller set.
Do you think I am just better off going with a new unit?
If so what brand and where is the best place to purchase?

Thanks much.

[MKMike]

While the video also shows the bearing being replaced, it may not be necessary.

It probably isn't the bearing, since the noise goes away when the ac is on.
What causes the grinding sound, in many instances, is the clutch plate scraping against the pulley because it isn't clearing it like it's supposed to.
With a mirror and a flashlight, you can actually see the the shiny surface on the pulley, where the clutch plate is grinding .
Just looking straight down at it, you can't see that without the mirror.

You can remove the belt and check for wobble/play in the bearing and also spin the pulley by hand , feeling for any roughness to determine if the bearing has gone bad.
The compressor doesn't have to be removed from the engine compartment to replace the clutch plate---or even the bearing, but I believe you do have to unbolt it from its mount to get the room you need.

Hard to say what is your best option.
The clutch plate is around $60 and can be replaced without opening the system.
The entire compressor is about $175 but you need to get a shop remove the refrigerant, so you can replace the compressor plus the additional parts thatmust be replaced and then have the shop vacuum down the system and recharge it.
Whenever the AC system is opened up, you have to replace the receiver drier/accumulator assembly and the orifice tube also has to be replaced in order to have a valid ac compressor warranty.
Nowadays, you can't just empty the system without the refrigerant recovery equipment without breaking environmental laws.
If you have the manifold gauges and a vacuum pump, then all you would need the shop for is the emptying of the system.
New is the better way to go with compressors, when you factor in the expense of having the R134a removed, etc.
Delphi and ACDelco are the best for compressors.

[jdecker]

When my car did this it was the clutch bearing, the noise goes away when the clutch engages because the pulley is no longer spinning on the compressor input.

Having said that I was able to pull the clutch (I had to rent a special clutch puller) and reinstall it without removing the compressor lines by working through the passenger fender well. I had to take the clutch pulley to a machine shop to have the old bearing pressed out and the new bearing installed. Pulling the clutch with the compressor still on the car wasn't the funnest thing I've ever done, but it can be done.

[dougtoth]

MKMike.
I am going to just replace the clutch plate on the compressor.
That way I do not have to open up the system.
My brother in law has done some before and is going to help me.
Do you know what the part number is that I need to order?
Again it is for a 2001 Pontiac Bonneville SLE.

Thank you.

[MKMike]

http://www.rockauto.com/en/catalog/pont ... lutch,6572
under Heating and air condition you find ACDELCO 154685
Look on the Pontiac Bonneville Club Vendor's forum where RockAuto provides a discount code for Pontiac Bonneville Club members to use.

[dougtoth]

MKMike.
One last question.
Will I need a puller if I am just replacing the clutch plate only? (bearing is fine)

Thanks.

[dougtoth]

After I install the clutch plate does anyone know what the gap dimension is?
I believe either .025 or .030.

Thank you.

[MKMike]

MKMike.
One last question.
Will I need a puller if I am just replacing the clutch plate only? (bearing is fine)

Thanks.

You do need a special tool, as shown in the video after the 6 minute mark.

The tool is inexpensive enough and can probably be borrowed from AutoZone or similar.
You can buy a whole tool kit for under $35 from Amazon
Astro 7886 A/C Compressor Clutch Installer/Remover Kit
The gap should be set to .015 to .020 inches

[dougtoth]

MKMike.
Thanks for all your help.
Will advise when complete.

[dougtoth]

Just a follow up on the A/C clutch replacement.
I installed the new one today with a lot of help from my brother in law.
We installed it without taken the unit off.
We even left the belt on.
The only thing we took of was the ground cable to get more room.
It took about 2 1/2 hours.
The easy part was getting the old one off.
The hard part was getting the new one back on.(set gap at .020)
You have to match the key on the clutch with the slot on the compressor which was difficult and took a lot time.
I used clutch part number 15-4685.(AC OEM)
I also purchased an Astro kit number 7886.
This is an install/removal kit.
Without this kit it would have been impossible to do.
Thanks to MKMike for all of his input and knowledge.

[MKMike]

No problem. Glad to have helped.
Thanks for reporting back.
Very interesting to learn that you didn't even need to unbolt the compressor to do it.

[Jason H.]

I am having the same exact issue with the AC clutch on my '01 SE. Thank you, Doug and MKMike for all of your knowledge! I will attack this soon as I am not a guy that likes to run the AC....I like having the windows open. Sometimes, the noise bugs the crap out of me.