A/C clutch coil dilemma?

Tiny
SHANE TAYLOR
  • MEMBER
  • 2002 CHEVROLET TAHOE
  • 5.3L
  • V8
  • 2WD
  • AUTOMATIC
  • 350,000 MILES
Hi 2carpros, here with another diy Delima, I recently lost cold air in my vehicle listed above, a buddy of mine did a little testing and told me looks like my A/C coil wasn't engaging compressor, so I purchased a new clutch pulley coil kit and removed old ones and installed new coil, pulley anx clutch with proper gap tool for clutch, upon completion I had cold air and it was great, I idled formaybee 10 minutes and then drove it aproximatley 3 miles home and when I got home backing in driveway I thought dang no cold air, parked it and looked under and saw the coil wire was still plugged into plug but was either burnt or grinded completly off coil, I removed the clutch pulley and coil and these pics are what I saw, coil looks melted, pulley sounds like gravel inside, coil was all wobbly, but both c clamps were still holdin on but looks like been thrAough a, war.I ordered new kit, and a new blower motor and resister and I wanna know whst all do I need to check with multimeter and gauges, what numbers am I looking for and anything else I need to check in order to insure this dosent happen again, also the blower motor resistor showed ol when tested the two prongs on ohms indicating bad componet correct?Would a faulty resistor cause this irregular voltage through coil, im not sure wether the wirecwas melted off or grinded, pully sounds awful and coil was loose fitted like it was banged around.
Wednesday, September 10th, 2025 AT 11:09 AM

17 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 54,137 POSTS
I don't see any pics, can you please reload them? So the blower motor circuit does not affect the AC clutch coil. It sounds like the bearing of the pulley went out and caused the damage to the new clutch coil. Please let me know if you need anything? If you need help with the blower motor please start a new question, we only handle one problem per thread, please post your new question here, you must be logged in.

https://www.2carpros.com/questions/new

Cheers, Ken
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Wednesday, September 10th, 2025 AT 1:11 PM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
Thanks Mr. Ken, I don't have any problem with the resistor outside of if they could be linked, and you answered that question. I'm guessing this is not a ordinary thing to happen to brand new parts. Should I check the plug with a meter to insure proper voltage is being delivered or anything else I should check either before or after I install new coil kit?
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Wednesday, September 10th, 2025 AT 1:55 PM
Tiny
KEN L
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It kind of looks like the coil windings spun on the compressor? How does the bearing feel?
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Wednesday, September 10th, 2025 AT 5:38 PM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
Loose and like gravel is inside of it, what causes the coil windings to get spun on compressor? I'm not sure if I even know exactly what that entails.
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Wednesday, September 10th, 2025 AT 7:00 PM
Tiny
KEN L
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If the bearing feels bad, then that is what the problem is. Did you get the C installed correctly of the clutch coil before the bearing hub correct?
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Thursday, September 11th, 2025 AT 9:17 AM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
As far as I can remember yes. However I double and triple checked on the new kit, those c clips seem like they should fit in the groove better but they are in and tight, I gapped the clutch and reassembled all hoses shroud, fan ect thst I removed, also got thst blower andcresistor done and havny test drove yet but I did run in driveway and ac blew cold.I appreciate u Mr Ken, yet again you and 2CarPros has helped with another repair. You guys rock!
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Friday, September 12th, 2025 AT 10:54 AM
Tiny
KEN L
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Hello Shane, thank you for the well wishes. Let me know if you need us for anything else :)
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Sunday, September 14th, 2025 AT 10:14 AM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
Hey Mr. Ken, if I have a problem dealing with the same thing we last talked about do I continue here or start a whole new thread?
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Thursday, September 18th, 2025 AT 1:46 PM
Tiny
KEN L
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So what is happening? Can you turn the clutch on the compressor, does it turn smoothly?
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Thursday, September 18th, 2025 AT 4:19 PM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
  • 2002 CHEVROLET TAHOE
  • 5.3L
  • V8
  • 2WD
  • AUTOMATIC
  • 350,000 MILES
Brief history, ac went out, chsnged coil and clutch, worked for 5 miles broke, upon inspection the pulley had horrible grinding and somethjng either grinded or melted off plug for coil, so I changed pully, coil and it worked for a few days, what currently happening is upon starting ac the 10 amp fuse next to relay pops immediately.I have a cave mans knowledge of electrical matters, limited tools but I need step by step guidance to troubleshoot, idid a continuity test on a unplugged coil and 3.6 was the result. Am I right in saying I need to check the wire from 87 on the relay?If so how do i?
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Thursday, October 9th, 2025 AT 1:12 PM (Merged)
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 110,176 POSTS
Hi:

Ken is the man when it comes to AC-related issues. However, I just wanted to provide you with the diagnostics for testing a relay. Take a look at this link.

https://www.2carpros.com/articles/how-to-check-an-electrical-relay-and-wiring-control-circuit

If you are questioning the relay itself, switch it with a different one from the box that has the same part number to see if the 10-amp fuse still fails. If it does, then we have a short circuit between the relay and the compressor or within the coil itself.

At that point, narrow things down by disconnecting the compressor to see if the fuse still fails. If it doesn't, the clutch coil is the issue. If it still does, the wiring between the relay and clutch oil is shorted to ground.

I hope this helps. Ken will see this and add to any additional questions you may have.

Take care,

Joe
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Thursday, October 9th, 2025 AT 6:36 PM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
Thanks for the info joe!I will be giving it another try today and I will get back with results.
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Friday, October 10th, 2025 AT 8:57 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 110,176 POSTS
Hi:

You are very welcome. I hope it helps.

Take care,

Joe
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Friday, October 10th, 2025 AT 8:24 PM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
Well I swapped relays with horn and it worked so that is good, I disconnected the coil plug, left the pressure sensor in back of the compressor and with truck running turned on ac and no fuse blown. However with the coil plugged in I get immediate fuse blowing. It shows a 3.5 ohm on my meter, its a brand new coil, the last one I installed the pulley went bad and the coil looked melted and coil wire was either burned or melted off within 5 miles after install, blew cold for those few miles and upon installing this new coil I had cold ac until those fuse's started popping. Started out taking 20 sec to blow then 10 now its immmedieatly after turning on ac.I wonder if its a bad compressor
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Saturday, October 11th, 2025 AT 6:55 AM
Tiny
KEN L
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It sounds like the coil is bad, there is no other reason for the fuse to blow. I would get another one. Can I ask what brand the replacement coil is?
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Monday, October 13th, 2025 AT 11:15 AM
Tiny
SHANE TAYLOR
  • MEMBER
  • 22 POSTS
Did u mean what brand is the replacement coil?I mzy be able to research my amazon history but this is the second coil ive changed and I know I used two diff brands. First one worked for 5, 6 miles then evidently pully went south and the power wire either melted off or was ripped or grinded completly off, it looked melted in the coil where the magnet is and pully sounded like gravel when spun, bought a more expensive one and it lasted mabye a week or so but I dont drive much, def was a very short time. Is there a way to check the compressor to rule it out?Thanks mr ken
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Friday, October 17th, 2025 AT 12:58 AM
Tiny
KEN L
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No problem Shane, I would get an AC Delco unit, there are so many super cheap parts out there that don't work or short out quickly used compressor from ebay and install it, this should take care of the problem, this video can help you vacuum down and recharge the system .

https://www.youtube.com/watch?v=4EqdrBVb0sY&pp=0gcJCfwJAYcqIYzv

Please let us know what happens.
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Saturday, October 18th, 2025 AT 8:06 AM

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