PeachParts Mercedes-Benz Forum - View Single Post - 82 300D How difficult to change a/c clutch?

rrgrassi · #18 07-07-2011, 02:21 PM

Ok, I FINALLY did this job. (4th of July Weekend) The way I did it was a total PITA!!!! I'm going to invest in one of those mechanics mirrors!!! It would not have been so bad if I had known these two things...

1. The center bolt was missing from the compressor shaft. I had to remove the compressor with the lines still attached...nasty job. I did mount the compressor in it place, so re-assembly was "in situ", and was not a bad job at all.

2. The idler bearing was SPECIAL ORDER only from the chain parts houses. It was a PITA to pound out of the clutch hub.

Parts bought:

Replacement compressor shaft nut. It is not metric, 3/8" x 24 thread pitch. 9/16 socket fit better than the 14 mm socket.

New compressor V belt

BCA bearing from Greenville Bearing Supply (The original bearing was an SKF BA2-6508.)

What I did...Started in July 2nd. Finished on the evening of July 5.

1. Round up the needed tools: 19 mm gear wrench, 10 mm combo wrench, 13 mm socket and 13 mm gear wrench (For the power steering pump belt removal), clutch plate puller borrowed from O'Reilly and Clutch hub puller from AutoZone.

2. Spent about an hour tring to remove a non existant compressor shaft nut.

3. Spent another hour finally removing the compressor from it's mounting bracket to find the bolt was missing. Removing the tranny fluid line and moving fan shroud gave some extra room.

4. Attached clutch plate puller and removed the clutch plate. The key stayed on the shaft.

5. Removed the clutch hub snap ring.

6. Attached Auto Zone Hub puller and pulled off the hub.

7. Spent 15 minutes trying to pound out the pulley bearing. Found out the bearing must be pounded out from the back of the pulley, not the front. There is a lip that limits how far the bearing can be pressed in, from the front.

8. Spent another 45 minutes pounding out the bearing from the back.

9. Spent a few hours washing hands and trying to track down a replacement bearing. (Websites showed bearing in stock...stores said special order after I drove to them) Bearing supply house was already closed and would not reopen until July 5. It was a 4-7 day wait for the parts houses to get the order in.

10. Spent 2 hours remounting the compressor.

11. Washed hands for 3 hours.

12. July 5...purchased replacement bearing for $37.50 at the bearing supply house...it was a few dollars more that AutoZoo, but was BCA branded, not POS Murray Air.

13. Got home and then...pounded in the new bearing. Much quicker since the shop where I work made me a tool the fit the bearing nicely.

14. Installed the hub. (Tapped lightly with a hammer, using 1/4 in plywood as a pad.)

15. Installed snap ring.

16. Using the clutch plate installer, installed the clutch plate, and left a .25 inch gap between clutch plate and hub. Test spun pulley to check for any drag. All was good.

17. Removed power steering belt.

18. Installed compressor belt and adjusted.

19. Reconnected tranny fluid line.

20. Reinstalled and adjusted PS belt.

21. Washed hands again...

22. Tested, and now have nice cold air again...

So, this job CAN be done on a w123 with out remiving the compressor...