A/C clutch shim procedure for S60

Checking the clearance

I’ve confirmed that my AC clutch is not engaging properly and that it could be because of wear to the clutch plate . I’ve read several posts about shimming the clutch plate so that the gap is return to within spec. I’ve seen instructions posted for other Volvo’s but not for the S60. Does someone have instructions on how to do this for the S60, or at least instructions on how to remove the AC clutch pulley.

Here’s the now famous DIY procedure to fix your air conditioning with a AC clutch shim, but for the Volvo S60. If your AC blows cold for only 5 minutes, and you’ve recharged the R134a, this may be what you need to do.

AC clutch shim procedure for S60





The following images are from Volvo and describe replacing the magnetic clutch compressor.

clutch plate

clutch plate, shims

Pull off the pulley. Use puller 9995598 and socket 9995599

- Remove the magnet coil.

Install a new pulley. Use puller 999 5598 and socket 999 5600

- Install the snap ring.

- Install the shims.

Install the clutch plate

AC clutch shim procedure for S60

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Date July 21, 2010

9 responses to “A/C clutch shim procedure for S60”

  1. Guy Pearson says:

    Please before any of you try the A/C clutch shim ordeal. Try first wiring a 30 amp(fog light)relay into the power supply to clutch. Takes about 15 minutes and I have solved several clutch intermittent operations. I found on every car the line voltage to clutch was 7.5-9 volts.

  2. […] refrigerant charge… warm air, revs dropping every 10 or 20 seconds, etc.. Here’s how to shim the AC clutch on an S60. Here’s how to shim the AC clutch on an 850, V70/XC70 up to 2000, S70, or […]

  3. Josh Poole says:

    Guy, can you expound on this? How is the relay wired into the car’s electrical system?

  4. Guy Pearson says:

    Sorry for the delay, use the wire to the coil as the switch wire. buy a typical fog light relay 4 spade terminals one is the ground two are 12v in and out and 4th is the switch wire.

  5. Guy Pearson says:

    479-957-6804 any other questions.

  6. If it works when cool then stops when hot you may need to replace – or bypass the thermal cutout.


  7. […] AC clutch shim procedure for S60 […]

  8. Scott me serve says:

    looking to do a clutch job myself are there any videos or good instructions out there. Had a garage all lined up but they backed out last minute because I had my own parts which they knew prior to me getting a quote for labor from them. Please let me know thx

  9. […] gap problem, which is commonly fixed with the classic AC bread clip fix. See images from Volvo that show the AC clutch gap. He came up with anĀ AC clutch gap magnetic […]

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