TD5 air conditioning compressor missing front plate on the pulley

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Originally Posted by Rosscoe68

While you are working around that area, put an engine saver(low water sensor) in the top bleed screw.

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No need for any new electrics, as I have a MadMan EMS2 < MadMan - EMS 2 > installed as you can see from the big chunk of plastic in the top coolant hose. It does the same thing as the Engine Saver < Engine Saver Land Rover Page >

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Coolant level alarm (via 2 ss screws as probes)

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However, your post has made me look twice at the location of the sensor. It's probably far too low for effectiveness. I guess I could either purchase a < Haydn Coolant Alarms - Sensor Land Rover Td5 - (Powered by CubeCart) > and wire it to that instead or get another top hose and see if I can cut out the bleed screw and fit the plastic coupling in there instead.

I had this same issue when I bought my D2. Found aircon wasn't cold, went to local aircon place expecting a regas. They told me the clutch was not present, said it was an easy fix. They had a part on hand, said it was a common clutch. Had it replaced within the hour including being shimmed up. Cost me $110 fitted.
That was a place in Ferntree Gully VIC if it helps!

Sent from my HTC_PN071 using AULRO mobile app

I bet they had a laugh about that one.

Regards Philip A

A great link that may be useful for anyone else with this issue in the future:

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Originally Posted by OffTrack

Land Rover DISCOVERY AC Compressor Clutch REPAIR KIT 2004 2005 A/C

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Also available on eBay http://www.ebay.com/itm/Land-Rover-D...item4abbd0a121

Also a good thread for pictures of it going wrong is http://www.expeditionportal.com/foru...lutch-meltdown

I removed my fan belt today. Found a bolt that threaded into the shaft and then put a 3/8" ratchet onto the bolt head. I moved the ratchet in order to turn the shaft of the compressor. The shaft turned easily with no significant force required. I am hopefully therefore that the compressor is internally in good condition and only requires a new clutch cover (or entire clutch).

As such I have ordered one from Land Rover Discovery AC Compressor Clutch Repair KIT 2001 2002 2003 A C | eBay

Adam (the seller) has been kind enough to include a new bolt and clip in the kit for no extra cost (even though they are not usually included as part of the kit).

With any luck, rebuild the clutch and have a working air conditioner again without any regas required!

Just a follow up to this for anyone reading it in the future. When fitting the replacement kit parts I broke the nose of the shaft on the compressor - about 5mm from the end there is a groove to accommodate a circlip - due to the groove the metal is very thin and when I was pushing the new clutch on it must of not been completely straight (it's a tight space to work unless you remove the radiator/intercooler or the compressor from the vehicle) and this gave way at the groove part - the end result being that I could still reassemble, but without the circlip to hold in place/secure.

I ended up fitting a second hand compressor.

So it's been a bit over a year now since this and it's happened again!

https://www.aulro.com/afvb/images/im...015/05/680.jpg
https://www.aulro.com/afvb/images/im...015/05/681.jpg

Note that one of the shim spacer washers has stayed there!

This time I found the front plate:

https://www.aulro.com/afvb/images/im...015/05/682.jpg
https://www.aulro.com/afvb/images/im...015/05/683.jpg

But it's a write off:

https://www.aulro.com/afvb/images/im...015/05/684.jpg
https://www.aulro.com/afvb/images/im...015/05/685.jpg

It's caught the engine fans idler pulley on the way down and grooved that and taken the tip of the corners off the fan blades:

https://www.aulro.com/afvb/images/im...015/05/686.jpg
https://www.aulro.com/afvb/images/im...015/05/687.jpg

Thankfully I had a spare replacement front plate and other components on the shelf from last year. The internal shaft in the compressor is still moving and so I assumed it was still functional. I reassembled, used Loctite Medium Strength (blue) Thread Locker on the bolt and shimmed it out. It seems to work, the air conditioner cut in and out but then the current temperature is 13*C and cooling (I can see snow on the top of the mountain from my house at the moment) so it's probably didn't need the air-condition for cooling!
I also removed the idler pulley and set it up in the drill press to spin it while I sanded it smooth again:

https://www.aulro.com/afvb/images/im...015/05/688.jpg

You are a hard man on gear! :) Not something that you want happening all the time! That plate could do some serious damage depending on how it fell and what it hit. :( Hopefully the locktight will hold the litte sod.
Cheers Scott

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Originally Posted by schuy1

You are a hard man on gear! :) Not something that you want happening all the time! That plate could do some serious damage depending on how it fell and what it hit. :( Hopefully the locktight will hold the litte sod.

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It would seem so! But the thing is that being in Tasmania I barely use the air-conditioner - most of the time I leave it on Economy mode to stop the air con cutting in and robbing engine power and so I don't get chilly air blasted at me!
I'm hoping it's just bad luck as a result of using a second hand used replacement part and will be fine now! See what happens!

I kind of wish I used High Strength thread locker now though rather than the medium.

Hello all,

Sorry to resurrect such an old thread. It seems like the most relevant place to continue the conversation.

After reading through some of the info here on this thread and others I have just ordered a denso AC clutch repair kit from a US eBay seller.
The seller does not, however, supply the bolt. They suggested I go to a local hardware store:

"The bolt is a standard 6 mm x 20 mm long bolt you can purchase in any hardware store. Make sure you are purchasing a high-grade bolt."

Can anyone steer me in the right direction for such a bolt? Bolts is bolts to me. I wouldn't be able to recognise a good one at Bunnings.

Also, what is the verdict on locktite. I have the common blue loctite, do I need better?