Ford Mustang (1999-2004) Service Manual: Installation

1. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor.

Clean the A/C compressor nose area.

2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil or equivalent.

3. Position the shaft seal and the special tool over the A/C compressor shaft.

4. Using the special tool, push the shaft seal onto the A/C compressor shaft until seated.

5. Install the shaft seal snap ring.

6. Carry out the A/C compressor external leak test. For additional information, refer to Component Tests in Section.

7. Install the shaft seal felt.

8. Install the A/C clutch hub spacer.

9. Install the A/C disc and hub assembly.

10. Using the special tool, install the A/C disc and hub assembly retaining bolt.

11. Measure and adjust the clutch air gap by removing or adding spacers as needed.

12. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor-3.8L or Air Conditioning (A/C) Compressor-4.6L in this section.

Evaporator Core

Removal and Installation

NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly.

NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator.

NOTE: If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. For additional information, refer to Section.

1. Remove the evaporator core housing. For additional information, refer to Section.

2. Transfer the components from the old evaporator core housing to the new evaporator core housing.

3. Install the evaporator core housing. For additional information, refer to Section.