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2003 Ford Windstar: AC Compressor Too Big To Get Ou


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boru45
Novice

Dec 4, 2010, 1:34 PM

Post #1 of 9 (12800 views)
2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In

The AC compressor on my Windstar seized, ruining the serpentine belt . . . and now it's about to ruin me!

After much research, I found a refurbished compressor that comes with a warranty . . . and I thought I'd try to install it myself. I'm a fair mechanic, but nothing to write home about.

Anyway, after a shop drained the refrigerant, I started in on the compressor. On this van, it's attached to the front face of the engine, below the alternator, and it has very little room between the engine block and the front grill/radiator. Once I got it unbolted and disconnected, I had a bad surprise. The compressor is too large to remove going up or going down. I spent a good hour trying every angle, and found nothing: there is no way to remove it from the engine compartment without removing something else.

So that's my question: what might be the best thing to target for removal, if I'm looking for more space in-between the engine and the grill?

I looked at the radiator, and considered that -- but I won't proceed until I have expert input. Other candidates might be the manifold of pipes below the compressor -- and I'm just gone blank on what pipes these were. Exhaust?

So . . . any thoughts? I'd love to hear from anyone who can help!

TIA!

~jesse


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Dec 4, 2010, 3:24 PM

Post #2 of 9 (12794 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In

A/C is an entity unto itself. If compressor seized there's a high likelihood of system contamination and replacing it alone won't plain up and work. Most all warranties will be void if you don't do an accumulator at the same time. This should be a CCOT (clutch cycling Orifice Tube) system and the "O" tube if clogged - we call that "Black Death."

I'll find the link that's real helpful if you aren't too discouraged yet. This compressor is listed as in stock at NAPA - NEW and take the rebuilt back. They have such a high rate of failure you have to start over again!

Any mess found at "O" tube than system flush is required. You must measure what comes out for oil from old unit, put or know that much is in replacement plus an oz. Some condensers and this could be one won't flush well and will flush better if laid flat out of vehicle.

If no black death you take the gamble and it can work. You decide it's your $.

You MUST be able to hold a full vacuum for your altitude for at least 30 min and charge near exact known weight of refrigerant. Too much it will choke and too little it won't move oil and back to needing a compressor again.

This is why it's so expensive - can't overlook details or short cut.

To get the old one out very well may require taking lots out of the way. Some may get out thru a wheel well - dunno on this one. Before you disconnect you should have checked for leaks elsewhere in the system. If that was the root cause it will just happen again.

Stinks - hard work and know how to use equipment.

Here's a link for just "Charging Procedures" if everything was going well with replacements............

http://www.aircondition.com/...-Charging-Procedures

Rare to seize by clutch but could. Did just the clutch weld up on you?

You can do it but it's not real DIY friendly.

Take your time to do this right ONCE or it can be Pandora's box.

Good luck,

T

Here was the part shipped or at a local NAPA "NEW" others would have new also.............
http://www.napaonline.com/...102003+50028+2028059

(edit to correct one spelling error only)



(This post was edited by Tom Greenleaf on Dec 5, 2010, 5:31 AM)


Sidom
Veteran / Moderator
Sidom profile image

Dec 4, 2010, 7:23 PM

Post #3 of 9 (12785 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In

I can't remember for sure but I believe the alternator & brackets have to come out on that one.

Tom has some very good points on how to go about this and what to do. Just stuffing a comp on this and you'll probably being doing this again rather shortly..... Hopefully you didn't add stop leak or any else but R134a to this system over the course of it's life and this isn't a case of black death. If it is.......everything in the system has to be changed or you will be dealing with premature failures for the rest of the vans life...

It there is a black, gooey, liquid type substance in there then that is a very bad sign.....


boru45
Novice

Dec 5, 2010, 4:54 AM

Post #4 of 9 (12777 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In

"To get the old one out very well may require taking lots out of the way. Some may get out thru a wheel well - dunno on this one. Before you disconnect you should have checked for leaks elsewhere in the system. If that was the route cause it will just happen aga"

Thanks for the long post. I apprediate all the warnings and tips, but I was just asking how to get it out. I know all the rest, down to the last detail . . . having watched a long video on the process.

So, anyway, I guess the next post said what I was looking for: how to get it out. Maybe someone will come along and confirm that the alternator needs to come off.

Thanks for the help!

~jessie


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Dec 5, 2010, 5:50 AM

Post #5 of 9 (12770 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In


Quote
Thanks for the long post. I apprediate all the warnings and tips, but I was just asking how to get it out. I know all the rest, down to the last detail . . . having watched a long video on the process.


Well, I guess you're a real expert now.......... Good luck with that .. You likely will be doing this job again..
Yes, the alternator has to be removed



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Dec 5, 2010, 6:04 AM

Post #6 of 9 (12767 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In

Best I could find is alternator and brackets need to come out and likely brackets holding compressor then it can come out from the top.

Just notes: about 2/3rds of A/C not working is from a leak and subsequent low charge. Low charge will still operate but cycle more than needed at first and lack of lubrication takes out compressors. IMO 90% of compressors that seize could have been prevented when noise was heard the first time.

Hey - many vehicles are tight underhood and this is no exception. Tons of heat under there too - more than average IMO stresses things out,

T



boru45
Novice

Dec 5, 2010, 6:05 AM

Post #7 of 9 (12764 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In


In Reply To

Quote
Thanks for the long post. I apprediate all the warnings and tips, but I was just asking how to get it out. I know all the rest, down to the last detail . . . having watched a long video on the process.


Well, I guess you're a real expert now.......... Good luck with that .. You likely will be doing this job again..
Yes, the alternator has to be removed


I'm not sure why I would need to do it again. I'm just bypassing the failed compressor, using a working compressor instead of an AC bypass pulley.

Maybe I'm wrong, but a replacement compressor will spin just fine . . . and the system doesn't need to be charged or checked, because it won't be operational . . . other than as a pulley for the serpentine belt to spin on.

I've already bypassed the AC on a previous vehicle, but that one had a bypass pulley. Worked like a dream.

~jessie


Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Dec 5, 2010, 6:14 AM

Post #8 of 9 (12758 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In


Quote
The AC compressor on my Windstar seized, ruining the serpentine belt . . . and now it's about to ruin me!

After much research, I found a refurbished compressor that comes with a warranty . . . and I thought I'd try to install it myself. I'm a fair mechanic, but nothing to write home about.


I don't see any mention of only using it just for an idler for belt routing in your previous post. If that's all your doing, fine. I wouldn't expect this system to work for any period of time in the end though.



~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.



Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Dec 5, 2010, 6:20 AM

Post #9 of 9 (12755 views)
Re: 2003 Ford Windstar: AC Compressor Too Big To Get Ou Sign In

jesse - if all you wanted was a pulley there I wish you had said that first,

T







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