Related issues surrounding AC compressor… (1 Viewer)

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Joined
Dec 21, 2022
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1,061
Location
Central Ohio USA
All,
1990, HDJ81, 1-HDT.
While driving this morning to a favorite local MTB trail, the following happened…..
1) highway speeds, windows up, AC on.
2) AC seemed to NOT be putting out the normal temperature air. It was warm (85F) so i chocked it up to the temp outside. It is afaik the original system.
3) A mild (electrical?) smell was noticed coming through the vents.
4) Sudden loss of airflow with ALL gauges except Fuel and Speedometer showing zero.
5) NO warning lights at all.
6) All lights continued to work, turn signals, head lights etc…
7) Clock and Stereo continue to work.
8) Smell of something continued and intensified.
At first I thought alternator, but NO lights indicating. I was off the highway on a side road so I pulled over to take a peek under the hood.
NO belts twisted or missing, I didnt hear any squealing or strange noises.
I thought possibly a fusible link had blown but wasnt sure.
I turned my truck around and headed home. NO strange noises or vibrations were heard on the 20 min drive back at highway speeds.
I wasnt sure if i could shut the engine down or start it again so i pulled all the way into my garage. The engine did shut down normally. I did NOT attempt a restart.
After clearing some space in the garage, i grabbed some light, popped the hood and here is what i found……
Clearly the AC compressor may have a bearing or seal issue. There is black lube as indicated in the pictures.
Why would the gauges that I indicated above suddenly die yet other gauges continued to work?
Are there multiple issues going on?
I havent checked any of the fusible links, the alternator belt is tight.
Is there some sort of electrical issue going on in addition to the obvious AC compressor throwing lube?
Thank you for any ideas/thoughts/questions.

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I think I’d address what’s obvious first and go from there. Confirm the integrity of all fuses and fusible links and replace the AC compressor after that’s squared away see what your gauges are doing.
 
I think I’d address what’s obvious first and go from there. Confirm the integrity of all fuses and fusible links and replace the AC compressor after that’s squared away see what your gauges are doing.
I checked all of the fuses….the 10A fuse for the gauges is blown. What would cause this? Seems unrelated. I am hesitant to replace the 10A fuse until I know why it blew. Checking everything else now.
 
Looks like the ac clutch is slipping.
It’s likely what looks like “lube” all over the engine bay is clutch material due to a seized compressor.
 
I checked all of the fuses….the 10A fuse for the gauges is blown. What would cause this? Seems unrelated. I am hesitant to replace the 10A fuse until I know why it blew. Checking everything else now.
The fuse did its job and would do it again so not to worry but I’d fix what I know is bad first. While you wait for parts, you can certainly perform a thorough wiring inspection.
 
The fuse did its job and would do it again so not to worry but I’d fix what I know is bad first. While you wait for parts, you can certainly perform a thorough wiring inspection.
Should I go for a whole new unit or try for a DIY rebuild? I am inclined to keep things easiER but I have the FSM.
 
If you have low volts to the compressor the clutch it will slip. That explains the smell. Heat=resistance..The 10A fuse is blown from the gauges it could have been caused by the slipping clutch.

Unplug the compressor clutch and change the fuse.
 
It’s likely what looks like “lube” all over the engine bay is clutch material due to a seized compressor.
Ok, yes, it’s definitely not lube, it feels like melted plastic as it is solid to the touch despite its liquid appearance. Might have been liquid for a short time.
 
Alright, I just took the belt off and disconnected the electrical to the compressor. I replaced the 10A fuse in the “gauge” slot. Some quick research through google brought me to Mud and to this thread….
Either the compressor is seized or the magnetic clutch failed. I turned the compressor pulley by hand with the belt off and it spins but with a grinding feeling. Would it be worth pursuing a mag clutch rebuild or not bother and go with a whole new compressor? Obviously, a new compressor install would involve depressurizing the AC system of R12. Then the rabbit hole continues…..do replace the whole system to have R134a? Yes, one direction is much cheaper (new mag clutch) but if the compressor itself is seized, a new mag clutch is pointless. I have the FSM open and disassembly and reassembly of the mag clutch looks fairly straight forward. To test the compressor, I would have to get some gauges and follow the FSM. Sigh. Maybe just take it to an AC shop and see what they think? Also, is it safe to fire it up now that the compressor has been removed from action? Thank you for all of the help and advise.
 
Thanks guys, starting research on a new compressor, an AC shop and possible R134a upgrade. I wonder if drain and fill with R12 would be just as expensive as the upgrade/change to R134a? R12 is pretty much NLMade and is apparently $$$$$.
 
Thanks guys, starting research on a new compressor, an AC shop and possible R134a upgrade. I wonder if drain and fill with R12 would be just as expensive as the upgrade/change to R134a? R12 is pretty much NLMade and is apparently $$$$$.
If they have the equipment they should be able to evacuate and refill the R12 of what is in your system if it hasn’t leaked out. R12 cools better than R134a. But apparently it destroys the ozone layer or some lie like that.

R12 manufacture in the US was outlawed in 1995. You can still get it in Mexico..
 
Thanks guys, starting research on a new compressor, an AC shop and possible R134a upgrade. I wonder if drain and fill with R12 would be just as expensive as the upgrade/change to R134a? R12 is pretty much NLMade and is apparently $$$$$.
I retrofitted a 1993 a few years ago when I overhauled the AC system. The parts listed in this TSB cost me $80 iirc. I also replaced all the O-rings. Not a big deal.

 
Chinese made……probably less expensive short term. How long have you had this unit installed? Any issues?
Ordering parts from Amazon is risky and unnecessary. My pump is 4 seasons brand. I got it from RockAuto in 2017 and still good to go.
 

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