Need help on repairing A/C clutch assembly ... replacement for missing pin?

I have a 1990 Plymouth Sundance, bought it new, have had it for 16 years, it's getting a little long in the tooth but I've kept it up mechanically and it's a good "running around town" car.

A couple of weeks ago, the air conditioning cut out. I took it to my mechanic and learned that what had happened ... since he found this part laying on the engine where it had come off ... was the plate that's the front part of the clutch assembly (you have this plate, then the clutch, then the coil, if that gives folks a better idea of what I'm talking about) had broken.

Of course you can't buy just that plate. You have to buy the entire clutch assembly. I tried the recyclers and they wouldn't sell the clutch assembly separate from the compressor, which is understandable.

However, I found a clutch and compressor assembly from a recycler, with a one-year guarantee, for a very good price and ordered it. I figured "what the heck," my mechanic could take that plate off to replace my broken one and if the rest of the clutch and compressor go out ... and they're all in good working order, FYI ... I'll already have the parts in hand.

The clutch and compressor arrived today ... and it's not going to work, at least from the standpoint of being able to take the clutch plate off and replace my broken one, because they're two different plates, even the shaft that goes through from the A/C to the clutch is different. On mine, there's a nut that holds the plate onto the shaft, along with one other part that I'm going to discuss later. On this one, there's an actual bolt that connects into the shaft, looks like it literally screws in. I imagine what the deal is, this compressor/clutch is not out of a 1990 Plymouth Sundance but will work on one if you replace the whole unit.

I'm sure the next question is "why not replace the whole unit?" My mechanic, who I trust completely from him working on my cars for years, says he would prefer not to do that except as an absolute last resort, because of the trouble in doing it, the fact that I'd have to recharge the unit after just recharging the Freon in my current unit, and because in his judgment it could touch off other problems elsewhere in my A/C system.

So, I sat that aside and went to the local parts store and purchased a new clutch assembly ... cost significantly more than the clutch/compressor I got from the recycler, but I'm trusting my mechanic's judgment on whether to change the whole thing or not ... took it to my mechanic and he said it will work fine, but there's one problem.

I mentioned that there's a nut that holds this plate onto the shaft coming out of the A/C in my car. There was one other thing, a little rectangular looking black metal pin, almost like a key pin or something. You can see the notch for this pin on the clutch plate. My mechanic says it fits onto the shaft to keep the plate steady. He says if you don't have this, all the parts will wobble, etc., and the end result will likely be tearing everything up.

The problem is, this little pin broke when the plate broke off on my car. And there was not a new one included with the clutch assembly.

I'm sorry to be going so long in getting to the point on this ... basically, can anyone tell me what this pin is called and how I might go about getting another one, or if it's not possible to get another one what might work as an acceptable substitute?

Because as I said, I'm trusting my mechanic's judgment in his opinion that the best course of action here is just fixing the plate instead of changing out the entire clutch and compressor. But if I can't find a replacement for this little pin, I may have to change out the whole thing and just keep my fingers and toes crossed and say a prayer.

Thanks in advance for any help.

Reply to
grghelb
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Sorry for duplicate post.

Reply to
Greg Bailey

The part is called a "key."

I've used the shank of a drill bit (cut to length of course) of the appropriate size when faced with this dilema. Even though the original "key" was square, there really is no reason that a round key (drill shank) will not work.

Reply to
aarcuda69062

Check out any Ace hardware for a straight key for this shaft.

Bush

Reply to
Bush

Replies inserted in quoted text:

I know exactly what you mean.

Yes, I've been down that road.

Makes good sense, but I already know what you are going to say next.

Yep, This is common. What actually happens is that the car maker dosen't use the same compressor on every car made that year. Sometimes they find a source for a cheaper compresor during the production run on a model and begin using the different compressor. They might even do it because they found out that the original compressor they were using had a problem, so they switched to a different compressor.

Exactly. Changing just the clutch is a much better idea if you can get away with it.

That pin is called a key. They come in many shapes and sizes. but you have to have one that will fit correctly, and you can not just leave it out.

Seems to me that the last time I bought a clutch, the key came with it. Maybe you should ask the parts store to check and see if the one you got had the key missing, or maybe they could get you a key for it.

Most parts stores or hardware stores carry an assortment of keys . You might be able to find one that will fit and buy just the key. You might even be able to make one if you find something close enough to fitting with just a little filing or grinding. Perhaps a drill bit the correct size, cut to length and ground flat if necessary.. Be careful though. Some times the key is half moon shaped (thats called a woodruf key) and the new key must be exactly the same shape. It must fit well or the clutch may begin to move back and forth on the shaft and eventually fail again.

As long as you are sure the compressor is still good, you would be better off just replacing the clutch. I wonder though, if the clutch plate did not maybe brake because the compressor locked up or something like that. Make sure the compressor shaft still turns freely and doesn't get in a bind, or you will just ruin the new clutch.

Good luck,

Reply to
Kevin

My mechanic checked the compressor, shaft still turns freely.

Reply to
Greg Bailey

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