AC compressor pulley removal problems

  • 4 POSTS
  • 2008 MERCEDES BENZ GL450
  • 6.2L
  • V8
  • AWD
  • 80,000 MILES

Hello. Very hopeful and grateful for advise on my car.
the serpentine belt broke, after replacing, it failed a week later. I noted then that the ac compressor pulley had a break in it, at the belt edge surface of the pulley.

Tried everything to get the single bolt holding the pulley on the compressor, with the compressor still in place.

long story short, the pulley broke to pieces in the process and the bolt subsequently broke off, leaving the threaded part flush with the pulley itself. Now I have a bearing with no pulley and a broken bolt keeping me from replacing the entire pulley.
With the fan and shroud and many top radiator /grill/ect. Removed to give access space, How do I get the broken bolt out along with the rest of this pulley bearing, and just slide on and secure the new one?
do I have to drill it out?
do I have to remove the compressor itself, then monkey with it?
drilling will destroy the threads I imagine?
either from the front, by taking out the radiator that's still in place
from the underside, removing the compressor to work on the broken bolt?

if radiator, looks like it has fixed lines on driver side lower?
if the compressor to remove, how to do so without loosing the freon in the system?

Please please please help me. What seemed right there in my face, sorta easy to fix, has become me taking the whole grill, top frame, fan assembly. Ect. Off AND still, cant get a single solitary bolt to come out.

I am stuck and immobile.
please enlighten me on how to do something.

Do you
have the same problem?
Monday, March 27th, 2017 AT 11:25 AM

1 Reply

  • 21,076 POSTS

I am afraid I do not have good news. These clutches are not generally repairable in the field. You are looking at replacing the whole compressor. In order to do that you also need recovery equipment and knowledge of how to balance the oil in the system.
These pulleys are pressed together using special tools to precise measurements done at the factory.

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Monday, March 27th, 2017 AT 1:04 PM

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