2004 Volvo XC90 2.5T FWD A/C Clutch Shim Repair

Here is some video of me repairing my clutch on my 2004 Volvo XC90 2.5T FWD A/C compressor. The common symptom is the A/C system warming up instead of cooling. When you turn the A/C system off (either by HVAC control switch or turning the vehicle off) the clutch and compressor cool down, and begins to work the next time you use the A/C system. Also, when the A/C systems begins to blow warm air, you can often tap the clutch to re-engage it, it is not recommended as the engine is running and can cause damage or harm to yourself.

[@TheTexasCoder]

Thank you sir, the wife was happy I got it fixed, it is starting to get crazy hot :)

[@Biff98]

I'm assuming you knew about the access panel by the front passenger wheel?? Just pop the tire off, then one or two bolts and you've got a nice access right to that area??

[@RayCasey2010]

Steve Smith yup. Saw that on youtube. Great video nevertheless but painful to know that he coulda just done it through the wheel well

[@TheTexasCoder]

I would be lying if I said it was picnic...Next time I do this, just to save my back, I am evacuating the whole system and yanking the radiator/intercooler/ac condensor out and saving myself the heart ache :)

[@THEMOWERMEDIC1]

excellent toutorial!

[@edag826]

Hi mate, i have exactly the same xc90 2.5T here with the steering on the other side. It keeps rolling backwards on uphills. Any idea what might be causing this 🙏 I'd be grateful if you could put me in the right direction. Cheers, Ed

[@TheTexasCoder]

Thank you sir, it was a bear working in the tight spot, but I was thankful I didn't have to evacuate the system...saved time and money! Thanks for watching!

[@bgilliam12]

Thanks, that's exactly what I have, 2006 Volvo XC90 2.5t FWD. I had the throttle body cleaned or the entire PVC and it cured the surge and running like new. Not a small job by any means though. I also just replaced the front suspension and rides so much better too. Just hit 105,000 this weekend. Thanks again for all your videos, always great quality and help!

[@Lorddarthvader1701]

This is cool I did not know you can rebuild the A/C clutch system, good video buddy.

[@johnt120]

Do you have a more detailed name of the spanner wrench you used? Can't find anything like that. Thanks!

[@robertanthonysanchez-wade9981]

On our 07 XC90 AWD, the ac blows cold air but does not cool the entire cabin, on hot days the cabin feels humid, third row ac cools normally though, I wonder if this is the issue.

[@jesspierce6226]

Having trouble with the little ring that goes back on under the clutch. Any suggestions? We have the clutch off and the original ring. The new ring is proving to be VERY hard to get on! Any help or suggestions very appreciated

[@TheTexasCoder]

Thanks for watching and for the comment! My model is a 2004 with the 2.5T engine. During those years (04-06) the 2.9 (V6) models with the GM transmissions had many issues. The 2.5T with the Aisin Werner transmissions seem to hold up well. I currently have 170,000 miles on the Volvo, and have not flushed the transmission. With this many miles on it, I am hesitant to change the fluid. It sounds bad, but I am going to wait till I have to rebuild the transmission, then flush at intervals.

[@bgilliam12]

I notice you have the same model as I do. How many miles do you have on yours now and have you changed the transmission fluid? Have you had any problems with your tranny or any other issues? Thanks

[@wtbm123]

Good video

[@Cheator40]

Nice repair but that didn't look like fun in that tight area.

[@TheTexasCoder]

Thank you sir!

[@bgilliam12]

Tanks

[@CooterPie420]

Pro