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AC Clutch Keeps Breaking the Wire

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Donut06, May 9, 2025.

  1. May 9, 2025 at 8:29 AM
    #1
    Donut06

    Donut06 [OP] New Member

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    Tristian
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    It's my first time using a forum like this so if I make any mistakes that's why.
    2006 Toyota Tacoma Access Cab V6

    A few years ago my AC clutch went bad. So I replaced it. That first one spun the entire clutch and cut the wire on the clutch. I chalked it up to me being new to this and probably didn't put it on correctly.
    After a year of not having AC I finally bought a new clutch. This time I watched the video about 5 times before and once during the installation. I thought I did everything completely correctly. I started the truck and my AC was working. I drove around and did everything I needed to in my day and went to bed. On the 3rd day I drive into work and I hear a grinding in the front end.
    I got to work and opened the hood only to see that the clutch wire on the AC compressor was again cut. And is now spinning with the clutch which is what im assuming the grind is.

    Before I attempt to put a new clutch on, I wanted to ask the forums to see if maybe my compressor is the cause or if I am just doing this wrong.
     
  2. May 9, 2025 at 9:01 AM
    #2
    Dm93

    Dm93 Test Don't Guess

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    Got any pictures?

    Are you getting the snap-rings in the grooves properly that hold the magnet and pulley on?
     
  3. May 9, 2025 at 9:05 AM
    #3
    Donut06

    Donut06 [OP] New Member

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    That was exactly what I thought my problem was the first time. I think that I got them properly in there. When I get home today I'm going to take the clutch off again. So I will send updates
     
  4. May 9, 2025 at 9:10 AM
    #4
    Tacoma Mike

    Tacoma Mike 48 Year Chrysler/Toyota/ASE/ Master Tech.RETIRED

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    Did you shear off the index pin?
     
    Dm93 likes this.
  5. May 9, 2025 at 9:12 AM
    #5
    burlyb

    burlyb Active Member

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    Agreed with Dm93. It's really hard to verify that the inner snap ring is seated because you can't see into the shaft. You need to wiggle the hell out of it and see if there is any lateral play. Even lightly pry behind it. And you need to make sure it's seated and aligned on the locating pin or the snap ring won't seat either. The impression for the pin on the aftermarket clutches isn't as clean or crisp as the original, so it's not easy to feel that it's firmly aligned. Lots of trial and error. Also, as mentioned in other threads, you need to have the shims just right (after making sure the inner snap ring is seated) or the clutch will drag, overheat and score the surfaces. I found that most instructions tell you to use the same number of shims that came off with the original, but aftermarket pulleys vary and I had to use way more than the two thin ones that were on my original clutch. After assembly, start the car and engage the AC. Watch to see if it firmly engages and doesn't slip. Then turn AC off and see if it disengages and doesn't spin with the compressor. Even a little rub will spin it slightly and wear it down prematurely (and melt the rubber inner core).
     
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  6. May 9, 2025 at 10:53 PM
    #6
    1 Limited Toyota

    1 Limited Toyota ISO XRunner body kit complete or pieces

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    Does the snap ring have bow? Some snap rings are side sensitive.
     

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