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Old 05-23-2018, 06:50 AM   #1
DET17
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Default '92 ZEXEL AC compressor clutch change in situ?

Any experience with just a clutch change? Charged system in my 92 745T, clutch is dead shorted to ground, a goner. I read the clutch can be pulled off with the 3 each M5 threaded holes to "jack it off" the shaft..... but after that the trail goes cold.

I've got a perfect donor clutch from another 92 with around 55K miles on it, compressor is locked up from sleeping 20 years.

Thanks for pertinent advice
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Old 05-24-2018, 06:34 AM   #2
DET17
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or..... does anyone have a late Greenbook which details clutch replacement for the 92's?
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Old 05-24-2018, 10:27 AM   #3
EivlEvo
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DET. I don't have the info you're after, but I'll tell you that I changed the AC clutch and shims on my Evo in situ so I'm not sure why you couldn't do it here?

Just a heads up because... magnets and stuff.
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Old 05-27-2018, 09:13 AM   #4
DET17
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I'll pull the donor AC compressor clutch off with M5 x 35mm SHCS, maybe 40mm. I'm going to put my gauges on the car this weekend to ensure it has a full charge of R134a. If not, might as well yank the entire compressor and swap with another "known functional" in my hoard.
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Old 05-28-2018, 06:35 PM   #5
DET17
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Well, considering I found the system showing 10 psi I didn't need to worry about saving the charge. Put my vacuum pump on and the system is nice and tight. Rather than disturb the current compressor, I decided to try and pull the clutch per the original intent. Not too bad thus far.... donor compressor center hub pulls right off with the 3 aforementioned jack screws. Pull the center bolt....remove an external snap ring that keeps the bearing on snout of the compressor. Tricky part.... the 3 phillips heads that hold the clutch windings, WOW are they tight and the screws are quite soft. Used the mini-ratchet with prodigious axial force to keep the Phillips bit fully engaged so they could be broken loose. Certainly feels like ZEXEL used a form of Loctite to keep them from vibrating out.

SO, I have the replacement and am in process with removing the dead solider from my compressor.
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Old 06-09-2018, 02:23 PM   #6
DET17
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Well today is the today she went together. I had my machinist buddy make me a cylindrical drive tool to center on the bearing in the Vbelt drive sheave bearing. Put a bag of ice on the center hub of the ZEXEL to help ease the drive into position, a light press fit or perhaps "line to line". Coated the hub of the compressor with light lube, centered things up and with a half doz. blows from the plastic "deadblow" swinging sideways the sheave & bearing registered fully on the hub. Cover plate on the bearing reinstalled, and my snap ring pliers barely fit but reinstalled the external snap ring. I left the radiator & fan in place while changing this clutch.... just had to remove/aside the charcoal filter assy.

This job is TIGHT, but doable in situ.

Last adjusted with the center drive plate and the 3 each M5 screws to get the air gap in the clutch between .3 and .5mm.... the only specs I could find via the web. Tested the new clutch with a 12V jumper wire and she actuates just like those engineers intended. JOY.

Going to vacuum it down, and install some 134a this afternoon. Sure hope my ECC is good.... put a spare (untested) to replace the original 92 unit with a 95 donor. Hopefully she's blowing cold here this afternoon.........
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Old 06-09-2018, 02:41 PM   #7
EivlEvo
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And this is with the low mounted compressor on the PS (LHD) side?

Did you do most of the job on your back or bent over?
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Old 06-09-2018, 09:06 PM   #8
DET17
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Yes, the late 7s and all the 9s have that driver side low mount for the AC compressor.

Car up on ramps (never trust a floor jack), remove the belly pan, and it wasn't that bad. I use a creeper which makes it easy to roll around beneath.

I did some work from the topside (with a row of kneeling pads across the top of the radiator & core support).....I can't do such work with the car sitting at ride height! Too old......
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Old 06-09-2018, 10:30 PM   #9
EivlEvo
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Good info. Hopefully that gets you some cool breeze.
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Old 06-10-2018, 08:02 AM   #10
DET17
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Quote:
Originally Posted by EivlEvo View Post
Good info. Hopefully that gets you some cool breeze.
Indeed. With the CCOT design of the late 7s & 9s..... I saw as low as 38*F in the center vent (cabin of the car started around 80*F when I left the house). When you install a thermometer in the center vents you can see the CCOT function; when the compressor cycles you will see the cabin air swinging from ~40*F then up to ~50*F when she's not compressing.

Sweet indeed, what with near 90*F and humid as hell in the ATL.
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