Safety First:
* Disconnect the battery's negative terminal before starting any work on the electrical system.
* Wear safety glasses to protect your eyes from debris.
* Use gloves to protect your hands.
* Recycle refrigerant properly. This is crucial for environmental reasons and your personal safety. Do not simply release the refrigerant into the atmosphere. Take the vehicle to a qualified mechanic or auto parts store that can properly evacuate the refrigerant.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Torque wrench
* AC clutch puller (specialized tool)
* Screwdrivers (Phillips and flathead)
* Wrench for the compressor pulley nut (often a large size)
* Refrigerant recovery and recycling equipment (unless taking it to a professional)
* Penetrating oil (like PB Blaster)
Steps (General Overview):
1. Refrigerant Evacuation: This is the most crucial step. Take the vehicle to a professional to have the refrigerant properly evacuated and recycled. Attempting to do this yourself without the proper equipment is dangerous and environmentally irresponsible.
2. Access the AC Compressor: Locate the AC compressor; it's usually on the engine's front, often driven by a serpentine belt. You might need to remove some components (belts, shrouds, etc.) to access it fully. Refer to your repair manual for specific removal instructions.
3. Disconnect the Electrical Connector: Carefully disconnect the electrical connector from the AC clutch.
4. Remove the Serpentine Belt: Remove the serpentine belt according to your repair manual's instructions. This will allow you to access the AC compressor pulley.
5. Remove the Pulley Nut: Use the appropriate size wrench and possibly a breaker bar to loosen and remove the large nut securing the AC compressor pulley. Penetrating oil may be helpful if the nut is stubborn.
6. Remove the AC Clutch: This is where the special AC clutch puller comes in. This tool is designed to remove the clutch assembly from the compressor shaft without damaging the compressor. Improper removal can easily damage the compressor. The repair manual will detail the correct procedure.
7. Install the New AC Clutch: Carefully install the new AC clutch, ensuring it's seated correctly and aligns perfectly. Tighten the nut to the manufacturer's specified torque (consult your repair manual).
8. Reinstall the Pulley: Reinstall the AC compressor pulley and tighten the nut to the specified torque.
9. Reinstall the Serpentine Belt: Reinstall the serpentine belt.
10. Reconnect the Electrical Connector: Reconnect the electrical connector to the AC clutch.
11. Reconnect the Battery: Reconnect the battery's negative terminal.
12. Refrigerant Recharge: After everything is reassembled, take the vehicle to a qualified mechanic or auto parts store to have the AC system recharged with the proper amount and type of refrigerant.
Important Considerations:
* Compressor Damage: If the AC compressor is damaged (seized bearing, etc.), replacing just the clutch will be a temporary fix. You may need to replace the entire compressor.
* Proper Torque: Using the correct torque settings is essential to prevent damage to the compressor and ensure proper functionality.
* Repair Manual: This is not a substitute for a repair manual. Consult a repair manual specific to your 1997 Mercury Mountaineer 5.0L for detailed instructions, torque specifications, and component locations.
This is a complex procedure. If you're not comfortable working on your vehicle's AC system, it's best to take it to a qualified mechanic. Improperly repairing the system can lead to further damage and potentially expensive repairs.
