TD5 air conditioning compressor missing front plate on the pulley

I'd go to a bolt place, ask for grade 8 bolt.
I always use red loctite, probly wrong one, but left over from Harley days

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Originally Posted by Wil2k

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.

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Do you have a local bolt specialist? Down here ours is called Nuts and Bolts Tasmania < Ashcroft Transmissions > - their name says it all. If you walked in there asked for a M6 x 20mm high tensile your guaranteed to walk out with the right thing and they're prices are cheap.
Alternatively, and possibly better actually, get down to your local Repco Auto Parts/Supercheap Auto and check out their nuts and bolts, they both usually stock the Champion brand of products which are high tensile and they should have flange head ones which are probably better suited for this application.

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Originally Posted by Wil2k

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

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Yep, use it, just a bit, don't go overboard. Blue should be fine - it's mid-strength I believe.

Just had this happen on our D2 - the front plate fell off and luckily only dented a few blades on the fan.

Is the car driveable with the A/C switched off? i.e. the pulley wont fall off?

thanks

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Originally Posted by jwb

Is the car driveable with the A/C switched off? i.e. the pulley wont fall off?

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Yep, should be fine. I drove mine like that for sometime without issue.

I recently had the AC compressor clutch front plate come off and thoughtfully deposit itself on top of the upper radiator hose so as not to be a bother to anyone by missing all the vital organs. I couldn’t find the missing bolt and shims but got hold of some second hand bits including flanged bolt and shims for $20 from Autocool Components in Lord St Perth - helpful guys.
Apparently the Denso 10PA17C compressor as used on Disco 2s is also used on many other vehicles with just the pulley and clutch arrangements varying slightly to suit. I have attached a useful Denso AC clutch repair manual I came across.Attachment 151073
The Disco AC clutch is recessed in the pulley so I had to bend a cheap set of feeler gauges at 90 deg to measure the gap. I used Loctite 243 (Blue) and tightened to 15Nm as the second hand bolt I used was supposedly off a Denso compressor but of unknown grade. Make sure you clean all traces of grease off the internal and external threads (e.g. acetone).

I replaced the bearing today as it thought it was the bearing that was faulty in the clutch pulley of my 2004 D2 TD5 but the rattle remains when the aircon switches off. Is it possible to refurbish the clutch plates themselves inside the pulley?
The checkered rivets on it look like the answer is NO, but I am wondering......otherwise I guess I have wasted a brand new bearing when instead a new pulley would have been the way to go. Thoughts?

Cheers, Peter

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Originally Posted by WTF123

otherwise I guess I have wasted a brand new bearing when instead a new pulley would have been the way to go. Thoughts?

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Not exactly wasted as your old bearing was probably getting on.
I'd start by getting another used unit and swapping the pulley over to see if it resolves the issue. If it does then you at least know where the fault is. Run out the new-to-you used-pulley for now, and consider a brand new one next time...

And of course that's true twr7cx. 😁
I'll find another pulley then I reckon I might drill out the rivets on this current one to see what's involved in repairing the guts of it.