AC Compressor Clutch Seized

Hello everyone!

Just bought a 2009 taco with a broken AC system. When you turn on the AC, a series of events happens: the AC compressor clutch spins briefly, causing a high pitched squeal and the engine starts to shudder. Then, the clutch stops spinning, the AC light starts blinking, the engine speed goes back to normal, and a slight burning smell is emitted. When the truck is off, the clutch doesn't spin freely, so there's definitely a problem there, I'm just not sure if it means replacing just the clutch or the entire compressor. I've tested the refrigerant levels, they're all good, and I've also tested the relays and fuses, which all work.

Any advice would be greatly appreciated! Hoping to fix this myself but not very experienced with this sort of stuff.

Thanks!

 

From your description it sounds like the compressor has locked up.

If that is the case then at a minimum you need a new compressor, if there is metal contamination in the system you should also replace the condenser, expansion valve, and expansion valve filter and flush all the lines and evaporator thoroughly.

 

How can I tell if there's a metal contamination?

 

You can't really until you remove the compressor and pour out the oil but if it's locked up the chance of metal contamination is high.

 

Ok, sounds like I have quite a project ahead of me Thanks for your help! Any advice for the process itself?

 

Recover refrigerant
flush ALL AC LINES (suction, discharge, liquid), flush evaporator. order a flush kit, use a solvent that does not leave residue
Replace compressor; get a delphi/mahle one. They are OEM.
replace condenser (contains dryer), expansion valve. Use denso parts. Denso parts are a lot cheaper than OEM and the Denso condenser has a serviceable dryer, OEM part does not. since the condenser contains the dryer, it should be the last part in. do not wait long between fully assembling the system and evacuation. the ambient moisture can saturate the dryer's desiccant
recommend replacing all the seals since you will have the entire systtem apart.
evacuate the system and recharge by WEIGHT.

 

Sounds good, thank you!

 

I will add save the Lock Sensor from the original compressor just in case, the Lock Sensor on some replacement compressors does not work properly and may result in a flashing A/C Light and A/C inop.

 

Another note, if you want to save money, you can order an OEM compressor from the dealer. It will come without the clutch and a couple other accessories (lock sensor, harness). You'll need to swap all these over
I believe the cheapest price I found for the dealer compressor was around $200.
Mahle complete OEM compressor is around $400.
it comes with lock sensor, new clutch, everything you need. plug and play + its what came with the car from the factory

regardless of which option you choose, please take note of the oil that comes in the new compressor and make sure it is sufficient for the entire system.
you can assume the system is empty of oil since you flushed everything out


heres an excellent video about AC flushing:
https://www.youtube.com/watch?v=N_msH6TX2W4

 

i had similar symptoms and all i had to replace was the AC clutch. I think i foound a replacement on ebay. scraps of rubber or something over time build up in there and cause it to lock up. there are a few good write ups here