2004 Freestar A/C repair

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2004 Freestar A/C repair

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Ford Forums >> Ford Trucks, Ford Vans & Ford SUV's >> Ford Freestar >> 2004 Freestar A/C repair

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2004 Freestar A/C repair - 8/15/2008 4:29:28 AM

Use Common Sense

Posts: 543
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Joined: 1/12/2007
Status: online

OK, My turn...

The A/C compressor on my 2004 Freestar Limited siezed up on me, so I''m doing the repair myself as usual. I have installed a new compressor, condenser, dryer/accumulator, rear expansion valve and Polymax non-hydroscopic oil. I will also be installing an in-line filter w/sight glass on the high pressure line before the "Y" to the front and rear evaporators. The front A/C lines have been flushed of all oil and debris, along with the rear evaporator and it''s return line. All that''''s left is removing and replacing the front orifice and flushing the high pressure side lines to the front and rear evaporators along with the front evaporator. The problem I have is trying to get the line broke open to replace the front orifice. The shop manual is useless at this point. Does anybody know what size these two nuts are? And how is one supposed to get them broken apart in such a tight area as the line with the orifice is basically butted up against the firewall? Thank''s for any help.

SIDE NOTE:
The compressor didn''t suffer from the dreaded "BLACK DEATH". It just started to chatter and siezed up. The oil in the system was still clean except for all of the nice shiny aluminum particals. Also, the system is supposed to have 13 oz. of oil in it. I have only recovered about 4 oz. so far. The compressor basically had no oil in it when I removed it. I suspect that my system was short changed with only 8 oz. of oil from the factory.

< Message edited by Use Common Sense -- 8/15/2008 4:33:35 AM >

_____________________________

2004 Freestar Limited 4.2 V6 w/Water Injection & Iridium plugs
2008 Mercury Sable 3.5 V6 w/Opened Air Box

AMSOIL Lubricants and Filters in everything

"Have a good day, and a better one tomorrow"

Post #: 1

RE: 2004 Freestar A/C repair - 9/9/2008 2:57:02 AM

Use Common Sense

Posts: 543
Score: 0
Joined: 1/12/2007
Status: online

Well, was finally able to get the line broke loose and the front orifice removed. Finally found in the shop manual the you have to remove the wiper arms, upper and lower cowling and air intake housing. This provided direct access to the fittings. Flushed the front evaporator and installed the new orifice. Buttoned the system all up and pressurized with nitrogen to check for leaks. Pulled a vacuum down to 240 microns and recharged with 53 oz of R-134a. Vent output temp is 44-45 degrees with a 87 degree ambient outside temp. Low side reading 47-PSI and High side reading 230-PSI. Both front and rear A/C working great.

Suspect my compressor failure was two-fold. I recovered only 7 oz. of oil from the system where it should have had 12-13 oz. I also split the compressor open and found surface rust on the steel valve plates

This project is completed, now I have that pesky little "TRAC OFF" gremlin popping up...

_____________________________

2004 Freestar Limited 4.2 V6 w/Water Injection & Iridium plugs
2008 Mercury Sable 3.5 V6 w/Opened Air Box

AMSOIL Lubricants and Filters in everything

"Have a good day, and a better one tomorrow"

(in reply to Use Common Sense)

Post #: 2