Clutch Rotor and/or Bearing Replacement HT6/HD6/HU6

Removal Procedure

Tools Required

1. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .



2. Remove the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub Assembly Removal .
3. Use the J 6083 in order to remove the following components:

•	The pulley rotor (1)

•	The bearing assembly retaining ring (2)




4. Install the J 33023-A to the front head.
5. Install the J 41552 down into the inner circle of slots (1) in the rotor.



6. Turn the J 41552 clockwise in the slots in the rotor.
7. Perform the following steps in order to remove the pulley rotor and bearing assembly:

7.1.	Hold the J 41552 in position.

7.2.	Tighten the puller screw against the puller guide.

7.3.	Remove the pulley rotor and bearing assembly.

8. Use the following procedure to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage:

8.1.	Remove the forcing screw from the J 41552 .

8.2.	Ensure that the puller tangs still engage in the rotor slots.

8.3.	Invert the assembly onto a solid flat surface or blocks.

Notice: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged.

9. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub.

Installation Procedure

Notice: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent.

1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation.
2. Use the following tools in order to align the new bearing squarely with the hub bore:

•	The J 41552

•	The J 9481-A

•	The J 29886

3. Drive the bearing fully into the hub.

The installer will apply force to the outer race of the bearing, if used as shown.




4. Place the J 33019 in the hub bore.
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the staking pin location.

Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin.

Important: Use care in order to prevent personal injury when striking the staking pin with a hammer.

6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing.




Important: Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing.

7. Stake 3 locations on the bearing race 120 degrees apart as shown.



8. With the compressor mounted on the J 34992 , position the pulley rotor (1) and the bearing assembly on the front head.
9. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
10. Position the J 8433-1 on the J 33023-A .
11. Assemble the 2 through bolts and the washers through the puller bar slots.
12. Thread the through bolts into the J 34992 .

Ensure that the thread of the through bolts engage the full thickness of the J 34992 .

13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head.

If the J 33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps:

13.1.

Loosen the J 8433-3 .

13.2.

Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head.




14. Use the snap ring pliers in order to install the following components:

14.1.

The pulley rotor (1)

14.2.

The retaining ring (2)

14.3.

Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate/Hub Assembly Install .

14.4.

Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .

Clutch Rotor and/or Bearing Replacement V-5 Conventional Mount

Tools Required

Removal Procedure

1. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .



2. Remove the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub Assembly Removal .
3. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring.



4. Install the J 33023-A to the front head.



5. Install the J 33020 into the inner circle of slots in the rotor.
6. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the segments between the slots in the rotor.
7. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to remove the puller rotor and bearing assembly.



8. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal.

8.1.	Remove the forcing screw from the J 33020 .

8.2.	With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto a solid, flat surface or blocks.

Notice: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged.

9. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub.

Installation Procedure

Notice: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent.

1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the bearing installation.
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092 , drive the bearing into the hub.

The J 9481-A applies force to the outer race of the bearing.




4. Place the J 33019 and the staking pin in the hub bore.
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the location of the staking pin.
6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019 .

Important: Do not allow a metal stake to contact the outer face of the bearing in order to prevent distortion of the outer race.

7. Using care in order to prevent injury, strike the staking pin of the J 33019 . Properly position the stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed down to, but not touching, the bearing.



9. Stake 3 places 120 degrees apart.



10. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on the front head.
11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
12. Position the J 8433-1 on the J 33023-A .
13. Assemble the 2 through bolts and the washers of the J 34992 through the slots of the J 8433-1 .
14. Thread the 2 through bolts into the J 34992 .

Ensure that the thread of the through bolts engages the full thickness of the J 34992 .

15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the front head of the compressor.
16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following steps:

16.1.

Loosen the J 8433-3 .

16.2.

Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the front head.




17. Install the rotor and bearing assembly retainer ring using the J 6083 .
18. Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate/Hub Assembly Install .
19. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .

Clutch Rotor and/or Bearing Replacement V-5 Direct Mount

Removal Procedure

Tools Required

1. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .



2. Install the compressor onto the J 41790-A .



3. Remove the clutch plate and hub assembly (2).
4. Remove the clutch rotor and bearing assembly retaining ring (3), using external snap ring pliers (1).



5. Place the J 33023-A on the clutch rotor.



6. Install the J 41552 down into the inner circle of slots in the rotor.

Turn the compressor pulley puller clockwise in the slots to engage the puller tangs with the rotor.

7. Hold the compressor pulley puller in place and use a wrench to turn the center forcing screw against the puller pilot to remove the clutch rotor and bearing assembly.

Installation Procedure

1. Position the clutch rotor and bearing assembly (2) onto the compressor.
2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing.
3. Place the washer (3) onto the body of J 33013-B .
4. Remove the center screw from the body of the hub and drive plate installer.
5. Install the center screw into the opposite end of the hub and drive plate installer.
6. Back the body of the hub and drive plate installer tool off enough to allow the center screw to be threaded onto the end of the compressor shaft.
7. Thread the center screw several turns onto the end of the compressor shaft.

Do not tighten the center screw on the compressor shaft.

8. Hold the center screw with a wrench.
9. Tighten the hex portion of the hub and drive plate installer body several turns.



10. Remove the J 33013-B from the clutch rotor and bearing assembly.
11. Ensure that the clutch rotor and bearing (2) is pressed onto the nose of the compressor far enough to clear the groove for the retaining ring.

If the clutch rotor and bearing does not clear the groove, repeat steps 7, 8 and 9.

12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1).

Ensure that the chamfer side of the retaining ring is facing up when the retaining ring is being installed.

13. Install the clutch plate and hub assembly.
14. Remove the compressor from the J 41790-A .
15. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .

Clutch Rotor and/or Bearing Replacement V-7

Tools Required

Removal Procedure

1. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .



2. Clamp the A/C compressor holding fixture, J 41790-A in a vise and attach the A/C compressor to the J 41790-A .



3. Remove the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub Assembly Removal .
4. Using external snap ring pliers (1), remove the clutch rotor and bearing assembly retaining ring (3).



5. Place the J 33023-A on the clutch rotor.



6. Install the J 41552 down into the inner circle of slots in the rotor.

Turn the J 41552 clockwise in the slots to engage the puller tangs with the rotor.

7. Hold the J 41552 in place and use a wrench to turn the center forcing screw against the J 33023-A to remove the clutch rotor and bearing assembly.

Installation Procedure

1. Position the clutch rotor and bearing assembly (2) onto the A/C compressor.
2. Position the J 33017 and bearing (1) from the J 33013-B directly over the inner race of the bearing.
3. Place the washer (3) from the J 42126 tool kit onto the body of the J 33013-B .
4. Remove the center screw from the body of the J 33013-B .
5. Install the center screw into the opposite end of the J 33013-B .
6. Back the body of the J 33013-B off enough to allow the center screw to be threaded onto the end of the A/C compressor shaft.
7. Thread the center screw several turns onto the end of the A/C compressor shaft.

Do not tighten the center screw on the A/C compressor shaft.

8. Hold the center screw with a wrench.
9. Tighten the hex portion of the J 33013-B body several turns.



10. Remove the J 33013-B from the clutch rotor and bearing assembly.
11. Make sure that the clutch rotor and bearing (2) is pressed onto the nose of the A/C compressor far enough to clear the groove for the retaining ring.

If the clutch rotor and bearing does not clear the groove, repeat steps 7, 8 and 9.

12. Install the clutch rotor and bearing retaining ring (3) using external snap ring pliers (1).

Make sure that the camphor side of the retaining ring is facing up when the retaining ring is being installed.

13. Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate/Hub Assembly Install .
14. Remove the A/C compressor from the J 41790-A .
15. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .