We have a 2004 Ford Freestar van with the 3.9L engine.
The AC compressor seized up and broke the serpentine belt.

We don't want to pay yet again to get the AC repaired, as this van now only sees limited local use.

I've looked and haven't found an AC Bypass Pulley for this van/engine.

Have any of you found a way to just use a shorter serpentine belt and bypass the compressor?
In looking at the belt run diagram, it looks like it may be possible.

Have any of you had experience with this problem?
Thanks for any advice.

 

If the compressor just seized/ came apart internally, then as long as the compressor clutch isn't hot/locked then the belt should spin freely on the outter compressor pulley.
You should be able to just unplug the compressor so no engagement takes place. Just not using the A/C won't due since the compressor still is commanded to run in Defrost modes to dehumidify..

With the belt off, if the outter compressor pulley spins free, then just unplug the compressor..

 

The problem is, the clutch is locked up too.
Even with the vehicle turned off, the clutch doesn't spin freely.
The whole unit is seized up.

 

Not turning the clutch face, if the compressor is smoked, it's not gonna turn..

The outer portion or face of the clutch hub assembly is keyed to the compressors shaft. Unless the clutch is dragging severe or has bound the clutch tight against central pulley, it should spin.

With the serp belt 'removed' , can you spin the ' outer' belt pulley? If not, you could remove the compressor clutch center bolt and pull the clutch hub face off. The compressors main pulley is snap ringed to the compressor nose and could run without the front section.

 

If you cannot get the A/C compressors belt pulley to freely spin after unbolting the clutch hub from the face of the compressor a 72" serpentine belt can be used to bypass the A/C compressor. I had to do this years ago on my Freestar due to an "On the road" failure. I installed a Duralast belt (#715K6) to bypass the compressor. I still keep the belt in my van.

 

There you go!

 

Thanks much for the info.
This compressor and clutch are clearly toast, and I was hoping I could hear from somebody who'd used a shorter belt to bypass the compressor.

Do I correctly assume your engine was a 3.9L/4.2L type?

Thanks again for the info.
I'll get the belt you used and try it.

 

You got it...4.2...

 

Thanks.

 

Finally got around to putting that belt you told me about on.

It was really tight but got it on.

Because of space constraints, we couldn't get the the serpentine tool to open the tensioner enough and had to pry the belt on the last bit.

It works, but hope it's not too tight.