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HOMESERVICE MANUALSDODGE AND RAM1999VIPER RT/10REPAIR AND DIAGNOSIS (SINGLE PAGE)HEATING, VENTILATION & A/C (HVAC)GENERAL SERVICINGHVAC SYSTEM - COMPRESSOR SERVICINGZEXEL ROTARY VANECLUTCH ASSEMBLYINSTALLATION
1999 Dodge and Ram Viper RT/10

Clutch Assembly: Installation

1999 Dodge and Ram Viper RT/10SECTION Installation
  1. Install coil in original position. Ensure electrical connector is aligned with indent in front of compressor head. Tighten screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC-3) and thrust bearing on installation bolt and insert through center of pulley. Finger-tighten pulley installation bolt into compressor shaft.
  2. Finger-tighten nut on installation bolt to align pulley to compressor. Hold end of bolt and tighten nut until pulley bottoms on compressor. Loosen nut and remove installation bolt, thrust bearing and drive plate installer. Install snap ring with tapered side out.
  3. Install thrust bearing on installation bolt and insert through clutch drive plate. Place original shims on installation bolt. Thread bolt into compressor shaft. Hold end of bolt and tighten nut until clutch drive plate bottoms out. Loosen nut and remove installation bolt and thrust bearing. Install center bolt and tighten to 115 INCH lbs. (13 N.m) using clutch drive plate holder.
  4. Using a feeler gauge, measure air gap between drive plate and pulley. Air gap should be 0.018-0.030" (0.46-0.76 mm). If air gap is not as specified, add or remove shims as necessary. Install compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs. (49 N.m) and rear bolts to 19 ft. lbs. (26 N.m). Connect clutch electrical connector and install accessory drive belt.
  5. Start engine and allow it to idle. Turn A/C on and cycle A/C compressor on and off 10-15 times to break-in clutch drive plate and pulley assembly.
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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.