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2002 AC compressor not pumping


freezer65
05-14-2008, 10:08 PM
I need to replace the AC compressor on my 2002 windstar. Repair shop wants $1000. $500 on labor alone, which makes me think it may be labor intensive. Is there a Windstar repair manuel that would give me full instruction on the whole process? I am pretty mechanically inclined, but I have never replaced the compressor and dryer before. I just need some step by step help.

wiswind
05-15-2008, 06:12 AM
They have this in the factory manual and in the AlldataDIY online manual.
Personally, I leave this type of work to a shop as they have the equipment to properly evacuate the system and install new R-134.
Very likely, the system leaked the R-134 from someplace.......hopefully your shop used a "sniffer" to determine where your leak was.
Mine went right to the compressor area......but did not pick up any signs there......so they put a dye in the system.....and had me come back another day.
The dye showed them that my evaporator coil was leaking.
This was a labor intensive repair as this is in the passenger compartment.
Also.....FORD redesigned the unit.....requiring that the complete box be replaced.......a good $450 for the part.
My shop found an aftermarket coil that was to the old design.....and that brought the cost of the part down to $128.

So....point is.....it is important to determine the source of the leak.....The shop originally thought that maybe a seal was leaking near the compressor....but diagnosis lead them to the coil......the original compressor was just fine......

mundy5
05-15-2008, 12:12 PM
I concur with Wiswind. these repairs are tricky and only a good diagnosis could yield the source of your problem. It is customary for shops to blame the compressor since that's the high fail part in a/c systems. but sometimes it's a leak that has made you lose all the refrigerant and therefore, your compressor is not running b/c of the lack of pressure.

Suppose for the sake of argument, the shop was right. Then like Wiswind says, you still need to find a way to evacuate all the refrigerant b/4 you take apart the system to replace the compressor and dryer. not worth it my friend unless you want to get some more equipment and figure out a way to have the evacuated refrigerant recycled somehow. not worth it in my opinion.

I would find a reputable shop and have them run a test preferrably with the dye as it will tell you pretty quickly (next day) where the leak is.

freezer65
05-15-2008, 11:00 PM
The compressor problem I wrote about. The line was fully charged with coolant. The compressor was not pumping and the defroster was not working. There are places in town that will discharge and recharge the airconditioner. The shop said that the compressor was being engaged by the clutch. But, the compressor was failing to do it's job.
It's sounds like my attempt to save a few hundred $'s may be futile. I just have a hard time believing that it cost $1000 to repair the airconditioner. Especially when I can get the parts at the autoparts store for $250 - $300. Compressor, dryer, ring, etc.

mundy5
05-16-2008, 09:08 AM
The compressor problem I wrote about. The line was fully charged with coolant. The compressor was not pumping and the defroster was not working. There are places in town that will discharge and recharge the airconditioner. The shop said that the compressor was being engaged by the clutch. But, the compressor was failing to do it's job.
It's sounds like my attempt to save a few hundred $'s may be futile. I just have a hard time believing that it cost $1000 to repair the airconditioner. Especially when I can get the parts at the autoparts store for $250 - $300. Compressor, dryer, ring, etc.

freezer,

We normally identify the fluid that goes through the a/c system as refrigerant or the old name "freon." The word coolant is reserved for the green or yellow stuff in your radiator.

Anyway, as I and Wiswind explained, the repair job is a piece of cake if there was no refrigerant in your system. But from what you have written, there is plenty of refrigerant which means that it needs to be safely evacuated and then new refrigerant inserted. The EPA does not allow shops to haphazardly remove them into the air. There are specific guidelines with which they need to work which makes it an expensive repair b/c of all the equipment necessary to do this job.

You are correct in that if you did this yourself, it would not cost much but you would also be breaking the law and not to mention increase the chances of damaging the a/c system further by introducing air and moisture into the system which will not make your situation any better than it currently is.

wiswind
05-18-2008, 05:29 PM
Maybe you would be able to get a shop to evacuate the system for you.....then recharge it once you do the work.
Of course, it will cost money to do that....as the equipment and the R-134 is not cheap......but it might save you some $$$
I would check into what it would cost.....and compare to see how much money you will save on the job.
Also....make SURE that you have very good instructions (not just a general guide) that tell you step by step what to do.....and that you have the tools......like any special tools to disconnect and connect the lines.

Another thing to think of......I have seen that the replacement compressors come with or without the clutch.......I would lean toward getting one with a new clutch.

I do not know your level of expertise......A person who does this for a living would not find it to be a major challenge.
If not real sure of yourself.....I would have someone who knows what they are doing perform the repair.
I am one of the take it to my mechanic folks for this (and a number of other) repair.

It sounds like your situation is different from what I had.....as you still have a full charge.
My case was one where I lost the charge due to a leak......and would call for one to locate the leak......and I did not want to see you shell out cash for a new compressor that you did not need....and would not solve the problem (leak at a different location).

Different states have different rules.....although I believe all outlaw just venting it to the atmosphere.
Wisconsin, until a year or so ago, did not even permit the R-134 to be sold to anyone other than a specially A/C licensed person....so no going to the auto parts store to get it.

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