Hi, I'm new here and looking for some advice regarding my 2001 Honda Civic EX with about 120,000 miles. Recently as I was driving, my AC clutch fell off. My mechanic said I'll have to get a new compressor to fix this, which is going to end up costing me about $500 for parts and labor. I'm really hoping I can simply replace just the clutch instead, and maybe even do it myself. I've read a lot of posts about similar problems, and it seems results will vary depending on the damage to the shaft splines. My question then is this: Based on the provided photos of the shaft splines, do you think there's a decent chance I can simply buy a new clutch and fix this without buying a whole new compressor? Thanks.

The piece that fell off. Looks like the interior splines are completely worn off. Will have to replace.



The shaft, before removing metal filings.



Close-up of the shaft. The splines look in decent shape to me.



Another view of the shaft. The splines need some cleaning, but there are definitely still grooves. Not enough experience to know if these are still good though.

 

I would try it. The splines look good to me. Just need to be cleaned.

 

Thanks for taking a look. From what I've read elsewhere, I'll need some shims to get some kind of alignment just right. Would you be able to explain to me what this is about?

 

I've not done it myself but you have to have enough space between the clutch and compressor. That's where the shims come in. They are little spacers. You use some shims and then measure the air gap with a feeler gauge until its within spec.

 

I see. Sounds like I'd need special tools then. Think it's doable without them? Trial and error?

 

The feeler gauge is only $5 or so. You can probably do it without. You gotta make sure the gap isn't too big that the clutch won't engage and that isn't too small that it's always engaged.

 

Oh I see. You're just talking about something like this?

 

Yes. That's the one

 

Great, thanks! By the way, given that the nut came off, any suggestions on how to prevent that from happening again?

 

Torque it to spec and you should be fine. I'm guessing that's the original compressor that's 16 years old now. It lasted this long without anything special.

Now if you still want to make sure it won't come off then add thread locker.