Generic P80 AC clutch shim , bread clip, zip tie thread

[erikv11]

It looks you are putting them in the right spot but you can't just force them in and expect them to necessarily fix it, I think that may be the issue here. The purpose of the method is to force the gap to close up some, you are pushing the flat disc downward toward the body of the compressor. In your first picture, it looks like the disc is pushed all the way, i.e. it looks like there is no clutch gap at all, you have pushed the clutch gap to 0.0 mm. That's not good.

You want to insert clips or zip ties (zip ties are my preference) such that they adjust the gap becomes approximately 0.3 - 0.4 mm. That's really thin, you need a feeler gauge to know for sure.

Here is a close-up of a zip-tie installed but if you look at the clutch gap it looks like it still might be too big, maybe they need to move the zip tie a bit to push the gap a little smaller:

[rspi]

This method is usually applied to a working system that cuts out when the compressor get warm/hot. So, it works for 5 or 10 minutes, then will not engage again because the clutch gap is to large.

[BlackThunder]

Well I removed the bread clips since it seemed like the gap was too close. I may monkey with the zip tie position - I'll need to pick up a feeler gauge and see what the gap actually is. I can charge the system again if it needs it but I'm not wasting the money on new R134 if the compressor won't even turn over.

I had a switch replaced but I don't know where or that switch would be. That was years ago - and it was done by a great shop. The actual A/C switch in the cabin on the climate control has lost its snap and feels kind of spongy. I have held it down for a long time to make sure it was making some contact but still no luck.

Any suggestions? Maybe AC is a too cool of a dream for me

Dustin

[vvvolvo]

I performed this fix on my 2004 Volvo s60, 11 days ago. More accurately, I used the "zip tie fix." I chose the zip ties because I could just reach straight down and put the zip ties on, and I feel like the zip ties might last longer. I have small hands so I just reached down and put two zip ties on each side of the 3 rings (total of 6 zip ties). (I don't see how anyone with actual man hands could do this, though. BTW, I'm a female. I bruised the backs of mine up pretty badly, but I was determined). It works perfectly! Did a 16 hour road trip with A/C all the way!

Now, I have some questions. I have an appointment to have the clutch shims removed. My mechanic is awesome and knew all about this issue and about how to remove the shims. I did the fix myself because his next available appt was 3 weeks out. When I mentioned the fix he suggested that I should just cancel the appt, if the fix worked. His concern is that the clutch may be fused to the compressor and need to be replaced if they damage it while removing it. Should I just leave the zip ties on and skip the professional fix? How long will the zip ties last? Can it cause damage to anything other than the clutch if I leave them on?

How long has your fix lasted?

[oragex]

There have been people using the fix for around 2 years without issue. Myself I have it but with thin metal pieces because I feel the plastic can melt. However no one will have the same usage of the A/C. Perhaps, as you mentioned a 16h trip, if you think you will be using it for many hours to come, I would go with the real fix. Never read yet about a fused clutch case as your mechanic mentioned. Perhaps just give it a try.

As a side note, the 'bread clip' fix must be done properly or it can prematurely wear the clutch plate. There must be an uniform gap of about 0.3mm all around the plate (as measured with a cold engine).

[vvvolvo]

I had read about people using the metal pieces and don't place much faith in the plastic either. I will have my mechanic give a shot at the real fix. Thanks.

[erikv11]

...As a side note, the 'bread clip' fix must be done properly or it can prematurely wear the clutch plate. There must be an uniform gap of about 0.3mm all around the plate (as measured with a cold engine).

This is a great point, thanks oragex.

@vvolvo: I would estimate that hundreds of people who visit the forums are now using zip ties, and I have never heard of a failure (even though there has probably been one by now, with hundreds of people, but I would guess most likely due to install error!). On my own cars the longest duration is going on about 2 years now, and the AC gets used year round (cooling in the summer, defrost on the winter). It sounds like you have a good and trustworthy mechanic, the only reason to do the clutch shims now would be if/when the zip ties fail.

[abscate]

I performed this fix on my 2004 Volvo s60, 11 days ago. More accurately, I used the "zip tie fix." I chose the zip ties because I could just reach straight down and put the zip ties on, and I feel like the zip ties might last longer. I have small hands so I just reached down and put two zip ties on each side of the 3 rings (total of 6 zip ties). (I don't see how anyone with actual man hands could do this, though. BTW, I'm a female. I bruised the backs of mine up pretty badly, but I was determined). It works perfectly! Did a 16 hour road trip with A/C all the way!

Now, I have some questions. I have an appointment to have the clutch shims removed. My mechanic is awesome and knew all about this issue and about how to remove the shims. I did the fix myself because his next available appt was 3 weeks out. When I mentioned the fix he suggested that I should just cancel the appt, if the fix worked. His concern is that the clutch may be fused to the compressor and need to be replaced if they damage it while removing it. Should I just leave the zip ties on and skip the professional fix? How long will the zip ties last? Can it cause damage to anything other than the clutch if I leave them on?

How long has your fix lasted?

Your mechanic is simply in awe of your awesomeness at fixing your own AC. The AC compressor clutch has to be removed with a puller to get the shims adjusted, which is a huge job, and it CAN go badly - stripped screws, bent pulley if it gets stuck - not to mention that on the later cars you have to unbolt and drop the compressor to get room to pull the pulley.

If your zip tie fix worked - stick with it!!

And congrats on getting it done yourself...tell your SO s/he owes you about 500 USD in saved labor costs to be lavishly spent on yourself or at your discretion.

BTW, I'm a female. I bruised the backs of mine up pretty badly, but I was determined). It works perfectly!

MVS - it just doesn't get better than this...

[osmium]

I performed this fix on my 2004 Volvo s60, 11 days ago. More accurately, I used the "zip tie fix." I chose the zip ties because I could just reach straight down and put the zip ties on, and I feel like the zip ties might last longer. I have small hands so I just reached down and put two zip ties on each side of the 3 rings (total of 6 zip ties). (I don't see how anyone with actual man hands could do this, though. BTW, I'm a female. I bruised the backs of mine up pretty badly, but I was determined). It works perfectly! Did a 16 hour road trip with A/C all the way!

Now, I have some questions. I have an appointment to have the clutch shims removed. My mechanic is awesome and knew all about this issue and about how to remove the shims. I did the fix myself because his next available appt was 3 weeks out. When I mentioned the fix he suggested that I should just cancel the appt, if the fix worked. His concern is that the clutch may be fused to the compressor and need to be replaced if they damage it while removing it. Should I just leave the zip ties on and skip the professional fix? How long will the zip ties last? Can it cause damage to anything other than the clutch if I leave them on?

How long has your fix lasted?

Your mechanic is simply in awe of your awesomeness at fixing your own AC. The AC compressor clutch has to be removed with a puller to get the shims adjusted, which is a huge job, and it CAN go badly - stripped screws, bent pulley if it gets stuck - not to mention that on the later cars you have to unbolt and drop the compressor to get room to pull the pulley.

If your zip tie fix worked - stick with it!!

And congrats on getting it done yourself...tell your SO s/he owes you about 500 USD in saved labor costs to be lavishly spent on yourself or at your discretion.

BTW, I'm a female. I bruised the backs of mine up pretty badly, but I was determined). It works perfectly!

MVS - it just doesn't get better than this...

I can't believe it's been five years since the original post. Could never get the shim fix to work well for whatever reason. So I've been living with the intermittent AC. Fortunately, there's only a few days in the summer where I wished the AC would work. The past few days have been some of those days.

While looking for something else here, I came across the zip tie version. Did it first thing Sunday morning. Got a 20oz can of AC Pro, and I had AC back.

While driving to work this morning, I noticed the car bucking a little bit. Could hear the clicking on the compressor at the same time the bucking occurred.

Turns out I only ran the engine at idle when I charged the system. Should of been done at 1500rpm

When I put the refrigerant can back on and ran the engine at 1500, the pressure turned out to be below the green area on the pressure gauge. Put in what was left of the can in and the pressure went up to about mid-way into the green. AC air was much colder and it's not cycling every 10 sec.

Zip tie is the way to go!


-Os

[vvvolvo]

I spoke to my mechanic after reading some of these replies (thanks everyone!) and he said that if it were his car, he would just leave it with the zip ties. He said not to worry about the clutch bending because he would fix that anyway if he could get it off (in the future). I checked the gap and it is good all around. Worst case scenario is that it either fails and needs more zip ties, or bends the clutch plate. I'm just going to leave them on and fix it when/if it fails. I'm just glad that my mechanic knew exactly what I was talking about and was willing to do the fix if I wanted it. I had gone to several others already, because my guy is in such high demand that there is a long wait for an appointment. Nobody else would do anything but replace the entire A/C system, even though I told them exactly what needed to be done. My mechanic is awesome! Thanks for your replies. MVS has been an enormous help to me. I like fixing my car when I can because I think it is fun and get enormous satisfaction from it.