01 S60 cannot remove ac clutch, even broke a screw

Tamasis · Post by **Tamasis** » 24 Jun 2014, 21:16

I have read so many posts about this ac clutch issue and so many people suggest doing it right and remove the shim instead of the bread clip/zip tie option. I used the harmonic balancer rental from a post a while back instead of making a steel square and I cannot get the clutch to break free of the compressor. I put a washer in the center of the balancer to cover that hole and allow the M6 to push against something. I'm doing this from under the car and through the wheel well. What am I missing? Everyone says it is so easy and I have been trying all day and during one of my attempts broke one of the M5 bolts off in the clutch plate. I am wanting to sell the car so I'd rather not give the new owners a fix that may not last. Anyone have any suggestions? They would be much appreciated. I am feeling very defeated and I'm pretty mechanically inclined!!

Post by **abscate** » 25 Jun 2014, 04:53

Many, many more people shim the clutch on the front side (front is the left side of car, front of engine) than removing/dropping the AC compressor and going through clutch removal.

I think your experience shows why. If one doesn't feel bread clips are a good solution, then shim stock from thin metal is still a lot easier than a difficult compressor removal.

I would cut off the bolt with a grinder, shim the compressor, document it for new owner, and point them here if they feel it is a bad fix.

I'll confess I've thought about dropping the my compressor on the next major job to shim it on the back side, but thanks for reminding me the hornets nest I might be swatting.

Post by **jimmy57** » 25 Jun 2014, 07:15

So the center bolt is out and you substituted a longer 6mm bolt as the point the puller uses to push against?
I did this about two weeks ago on the same year model car and the plate came off with no puller.

Post by **JDS60R** » 25 Jun 2014, 10:02

Your washer is holding the outer clutch plate in. The proper pulley bold fits down the threaded shaft (it has no threads) .
The outer clutch plate starts just outside the threaded 6mm hole. You are holding it down and bending the outer clutch plate.

Remove your waher and put a pin/nail/smaller bolt down the center hole. Then use the puller.
Or get the right puller. Most auto part store will loan you one. I am in mount juliet. If you are close I can help.

P.S. Always listen to Jimmy - he knows these cars like no one else does. Always good advice

Tamasis · Post by **Tamasis** » 25 Jun 2014, 11:45

jimmy57 wrote:So the center bolt is out and you substituted a longer 6mm bolt as the point the puller uses to push against?
I did this about two weeks ago on the same year model car and the plate came off with no puller.

Thanks Jimmy yes. longer 6mm bolt in the center and the washer I added covered the hole of the puller so the bolt had something to push against.

Tamasis · Post by **Tamasis** » 25 Jun 2014, 11:49

JDS60R wrote:Your washer is holding the outer clutch plate in. The proper pulley bold fits down the threaded shaft (it has no threads) .
The outer clutch plate starts just outside the threaded 6mm hole. You are holding it down and bending the outer clutch plate.

Remove your waher and put a pin/nail/smaller bolt down the center hole. Then use the puller.
Or get the right puller. Most auto part store will loan you one. I am in mount juliet. If you are close I can help.

P.S. Always listen to Jimmy - he knows these cars like no one else does. Always good advice

Thanks for your offer, I may take you up on it! There was a post off swedespeed that used a harmonic balancer as the tool, there is a hole in the center of this balancer. I used the washer to cover the hole of the tool so it wasn't under the bolt but thought it would be the place the 6mm bolt would push off. Will it work either way? Hole in center for bolt to pass through or not hole in center for 6mm to fight against? I am getting the clutch puller this afternoon from Autozone. If it doesn't work I will put it all back together and go the shim route.

Post by **JDS60R** » 25 Jun 2014, 16:57

I don't understand what you wrote.

You need a 6mm diameter or smaller shaft to go down the center of the clutch where the center bolt was. This shaft must stick out at least 1/2 in so the cover ( with its 6mm hole in center) can slide up.
Use the long shaft bolt in the ac compressor clutch kit as it reduces down to 6mm and has a 2 in section of 6mm. Its a 5 minute job with the correct tool.