A/C Compressor Nightmare!

[Big John]

Recently had to replace the A/C compressor on my '96 2500. Found out a few things the hard way.
1. compressor lists for $460 from Dodge
2. noone else in the Houston area, nor on the web had one!
3. Many suppliers and parts houses say they have one, but send you a compressor that fits all other '96 Dodge pickups EXCEPT the diesel ones!
4. Two week turnaround on a rebuild job.

I wasted a lot of time trying to get a compressor from 4 different sources that said they had one. They all turned out to be the wrong one. Every web site I checked with ( 5 in all )also thought they had the right one, but all were wrong.

I ended up after a week of searching getting one from Dodge. The one on my truck had gotten so bad that it was unsafe to drive. The bearing on the drive pulley was gone. I begged my local parts manager and got the price down to $360. Bought an orifice, dryer, and freon from the local parts house. The job itself went smoothly. Cool air again!!

I left my old compressor at the local parts house to rebuild and start a chain for future Dodge pickup owners. They already had someone waiting on one. If you have the same problem and can turn in the core, we may be able to have affordable compressors available to us.

------------------
'94 2500 Diesel Reg. Cab
Auto 3. 54 4X4 TST 230hp
"If you can't Dodge it, Ram it!
'96 2500 diesel clubcab 4x4 5speed

[This message has been edited by Big John (edited 05-27-2001). ]

 

[moparguy]

Big John, GREAT idea, sorry to hear about the runaround you had to suffer though.

 

[Sled Puller]

Hey,
If the A/C is really bad, and you can't get one, can you buy the non A/C belt and by-pass it?
Gene

------------------
CPFF's Dowell Pin Jig Available in GLTDR Region! 1997 Cummins Dodge 4x4 "One Piece At A Time" Bombed & Amsoiled. Amsoil Executive Direct Jobber, Member of: NRA Business Alliance, GLTDR, WANTED: Wrecked Dodges.
www.awdist.com

 

[radixr]

Gene,

Yes, in fact, that's what I am going to do when my A/C goes south. I almost prefer the poor man's air conditioning anyway.

 

[Missouri Mule]

Great idea for you members in the vicinity of the artic(North Pole) but a little to hot for us done here by the equator. (95 + degrees coming in thru the window at 75 mph are still 95 +)
Thanks but I will have mine fixed when it goes.
Side note: The Florida legislature passed a bill, stating that having A/C in a vehicle is a must in this state. That if a vehicle a/c system had a leak it was OK for certified technician to refill... .
Of course at 50 bucks a pound (R-12)getting the leak fixed would be the smartest thing to do.

------------------
Bill Thomas
Missouri Mule - 96 Wht 4X4 ST CC,5 spd, 3. 54, 8 ft bed, 1 ft high cheater boards.
99 Freightliner bl/wht FL60 ISB-5. 9 24v,215 hp,520 tq,6 spd, 3. 59 nsr,16 ft box, 19. 5 tires,Wt/gvw 11,000/23000

 

[Kodiak]

I haven't needed it yet (sound of knocking on wood), but a friend had good luck with this place
http://www.polarbearinc.com/main2.htm

They have a good selection rebuilds at good prices. It's a good phone number to tack to the wall!

------------------
'95 2500 CC, SLT, LB 2WD, auto 3. 54, 74,000--Westech gauges in Autometer pod, Prime-loc, Brite box, Back-off Box, White Night back-up light module, Line X, Walker muffler, Borgeson steering shaft, Geno's Crankcase Breather/Vent Tube Catch-All

 

[danandamy]

Was the compressor itself going out or just the idler bearing? I was wondering if the bearing was replaceable by itself like they are on alot of other makes of A/C compressors.

Daniel

 

[Andy Redmond]

Big John:

You should have called me, I could have helped.

Your problem sourcing the right compressor stems from a different clutch, 8 grooves rather than 5 or 6. As the diesel uses a wider belt.

The clutch is available seperately from Dodge, order the one for a 94 it fits up to current models, if you call Dodge on a compressor clutch for post 94 models the compressor is only available as an assy.

New Sanden compressors or clutches are readily available in the aftermarket world as well as a host of reman. products some good quality, some junk Napa ok, pepboys and others usually poor quality rebuilds.

The idler bearing is not available, unless you are a a/c rebuilder or have some volume bearing buying power. .

A new Sanden clutch, and clutch coil should be available for 170 rather than the 250 or so Dodge wants for the compressor clutch.

Likewise I could call my a/c source and inquire on an entire compressor assy. I'm guessing about $300.

Hope this helps.

Good luck and you need air in Houston!

Andy

 

[Big John]

Andy, thanks for the info. My problem did start out as a bearing problem only. I did not even go into the story on looking for rebuild parts. I wanted to put a bearing in it, a clutch, and run the compressor some longer. I have done this many times in the past with good success. I had ZERO luck finding parts. I did find one website in Japan!! that said they could get me parts if I had some tariff imports number I had never heard of and could wire them the money. ?!?
The longer I ran, the worse the bearing got, then the clutch came apart. After several days running with the smell of burning clutch I would no longer trust the compressor after a rebuild. It had gotten too hot too long. When I took it off, the pulley came off in my hand!
Maybe this post will help someone not go down the same road I did.

John

 

[RMidgett]

A/C Compressor Dead...Rebuild??

Howdy,

I had my A/C diagnosed today; the bad news is there is a major leak in the front of the A/C compressor. I was told that the new freon blew right out the front of the compressor.

Is there a seal that goes out that can be replaced? Should I seek a local rebuilder? What about online sources? Should I replace the drier as well? Other parts I should replace?

I can turn nuts & bolts to do the removal & installation & a family member can re-charge the system.

The truck is a '96 with 135K miles on it.



Thanks!

 

[Andy Redmond]

yes, it can be rebuilt, it sounds like the shaft seal is gone. Likely, the compressor shaft has some play and it finally took out the seal. Change the dryer, then the orifice tube in the condensor.



Evacuate and recharge w/ 134A



Good luck



Andy

Redmond Enterprises

Plano, TX

 

[HoleshotHolset]

I bought a brand new Sanden (came in Mopar box... . ) from a place in my hometown... . ready to bolt on.



I paid about $258 about a year ago..... he had quite a few of them in stock...

I bought my condensor from them too... . $120... .



Custom Auto Body & Sales of Gardner Inc

179 West Street

Gardner, MA 01440

978-632-7444



Nice folks to deal with... . and no I'm not affiliated with them.



Matt

 

[TSjodin]

I have a 94 and have a small leak at the coupling which goes to the condenser. I've noticed that the later models have a block which anchors the coupling from moving. I think that it's pretty low on freon now since it is not cooling very well and cycles quite a bit.

I have got the tool to take apart the coupling but have no idea of what kind of seal (I suppose it's an O-Ring) it is. Can I open the system, change the seal, close it up and recharge without evacuating the system? If I put a dryer in, where would it go and what type would I use? Should I use the freon with or without oil? How do you know when you need compressor oil?

Lots of questions, I know there's some member out there that knows cause I know we have alot of talent on this forum.



Thanks alot,

Tom

 

[HoleshotHolset]

The seal is an o-ring... good luck on getting the right part # from your dealer... . I ordered some and they weren't even close. Change the orifice tube while you're at it... . it's fitted into the lower tube of the condensor... .



Everytime you break any seal on an A/C system... it must be evacuated AND recharged... . I know... bigtime bummer.



The receiver drier is back behind the air filter assy... . right by the firewall... . Go to the dealer or a local shop for this... . but I personally think that people change these way too often.



If the system was properly filled with oil before you messed with it... and none came out when you broke any junctions or evacuated the system... then you won't have to worry about the level of oil...



Hope this helps,

Matt

 

[RMidgett]

Part # for A/C Compressor??

Does anyone have the correct part number for the Sanden A/C compressor on the 1996 2500 CTD? I have been told it is a 709GK series, Sanden part # 4682 by a remanufactured compressor supplier, but the question is whether it has a "CS" rear head & if the letters "GK" are stamped in the housing somewhere. Perhaps someone has one out of the truck they could look at & reply??



The local Dodge dealership told me the current replacement unit is a Sanden model 4889, part # 5505 5339 AH... any comments on this?



I can get a replacment from Polar Bear in FL for under $200 if we can nail down the correct part. Any & all help is appreciated...

 

[Andy Redmond]

Sanden Series 709, SD7H15, it has an 8 groove clutch, the Mopar no for the clutch for the 1994 model years and fits up to current is 04897625AA. about $300. for just the clutch...



As you have noticed other folks sell sanden products for much less and still make a living.



The compressor should interchange from 1994 to current.



One should evacuate the system when breaking it open. This pulls a vacuum and removes moisture from the system. Moisture ruins a/c parts, plus it doesn't compress well causing cooling performance concerns.



On the o-rings, get it apart and go to a good auto parts store and ask to look at their o-rings for A/C. They should stock assortments and sell oneses and twoses etc. They should be light green or medium "ford" blue denoting that they are compatible with the oil used in the 134A PAO/PAG. If they are not this color look on the packaging to assure they are compatible w/134A your freon charge.



Replacement of the dryer is mandatory if the system is open for very long or open and closed and not evacuated for more than 12hrs or so.



If I open a system, it gets a dryer, as its cheap insurance.



On oil capacity, if the refrigerant is recovered rather than vented, very little oil loss occurs. I would not add all the oil the manual suggests when changing a dryer, due to over oiling which can cause cooling performance issues.



Good luck.

 

[RMidgett]

Compressor Nightmare

Thanks, Andy. . you are a great source of info. We will see if Polar Bear has the right compressor based on your input.