New A/C Comp. Blown Up. What could have happened?

[Mekanik]

I was working on a 2008 expedition on Friday that had a blown up A/C compressor. There is a TSB for this that suggests two different methods for cleaning the A/C system of metal debris.

 

Method A: Use some ford A/C system flushing machine-We don't have one.

 

Method B: Use two new adaptor kits with a "pancake" filter in-line before the condenser after replacing the compressor- We don't have the two expensive adaptor kits, and neither do other local ford dealers.

 

Both methods require that both expansion valves to be replaced along with the manifold line after the compressor. It also says to either replace the condenser filter/ desiccant or just replace the A/C condenser.

 

I figured that if I replace both expansion valves, manifold line, and flush the evaporators and and condenser along with the remaining lines I would be OK. If that wasn't enough, i would run the system for an hour and then replace the newly replaces condenser filter/ desiccant. I figured it is basically a filter and it would catch all the metal if any that was left behind.

 

I took the filter out of the condenser and then flushed it out with the Ford solvent that is kind of like mineral spirits and there was a ton of metal in it. I flushed it until the solvent coming out was clean. I flushed out the condenser, evaporators, lines with compressed air. The evaporators and lines seemed perfectly clean. i think most of the metal was stuck in the condenser and the condenser filter cartridge.

 

Anyway, i get the whole system cleaned up and I really thought I got all the metal out. The oil capacity was 7oz. and that's exactly what I put in. 2oz. in the compressor, 3oz. in the condenser, and the rest in the evaporators. I sucked the system down for a whole hour to boil all of the solvent out of the system. After I charged it up with freon I ran the engine at 1200RPM.

 

The new compressor locked-up after 15 minutes.

I have never had something like this happen to me. I took the new compressor apart and noticed two things. There was metal in the oil and it seemed watered down, possibly by the solvent. I also noticed what looked to me like metal transfer from two of the pistons to the cylinder walls.

 

What happened????? Was it the solvent? Did that water down the oil and cause the compressor to get too hot? Did I not put enough oil in the compressor? The TSB actually said to put 2oz. of oil in the compressor, and that's what I put in it. I put 7oz. in the system, and that is what the spec is. The only two other things that I thought could have happened was some metal was still in the condenser. I flushed the condenser out with a solvent can at approx 100psi. and the A/C pressure is about 350psi. I could see how some metal could have gotten lodged loose by the A/C pressure. It seems like a far distance to go in such a short period of time, from the condenser all the way back into the compressor. And then there is the possibility that I got a bad compressor which I highly doubt.

 

I would like some input on why this happened.

[Aaron]

That solvent is a motherfucker to get out. I try and avoid using it. I load one of those little flusher deals up with brake cleaner and try and use that as best I can.

 

Last compressor failure I had was on an Edge, and they (hotline) told me to change everything, except the evaporator, after it ate a second compressor.

 

I'd bet the solvent contaminated/diluted the oil on ya. I hate that shit.

[Mekanik]

I have used brake clean several times without any problem. That solvent dosen't seem to evaporate that easy.

[Aaron]

It's real oily, eh? I found using that, and then brake cleaner even didn't get it all out.

 

 

And holy shit does it ever stink. I spilled a little down an evaporator tube and it absorbed right into the foam on the evaporator. Single cab truck, BLACK, outside in 100+ degree heat. It was not pleasant smelling inside.

[Jim Warman]

I've never been able to procure the pancake filters... I see them catalogued all over the place... but it seems like nobody stocks them or can get them or what-ever...

 

We did get a flush unit... the solvent stinks to high heaven (I direct our guys to use the provided breathing filter - ultimately their choice, but it amazes me to see somebody insist on using nitrile gloves because of the carcinogens only to.... but that's another thread).

 

Anyway, the flush unit has a lenghty air purge process to it and it does remove the solvent when performed properly (never hurts to give it an extra 5 minutes, either). Naturally, one is going to remove the receiver drier or suction accumnulator from the system...

 

An orofice tube system would have offered some protection but an expansion valve system will generally allow crap to go everywhere.

 

What you need to do is talk to who-ever is in charge of your equipment purse strings... You can't work without adequate tools. In a case like this, it doesn't take many fuck ups to have paid for the proper tools, anyway. There are places you can come up with a viable work-around... this isn't one of them.

 

FWIW, most of our techs have had the pleasure of using our flush machine... we have had zero for problems regardng legacy contamination of the system.

[Brad Clayton]

I remember when we got our flusher. It was at my old shop and the first time it got fired up was the last time it got fired up.....indoors that is. From there on whoever had to use it got the pleasure of working outdoors.

[Mekanik]

 

Anyway, the flush unit has a lengthy air purge process to it and it does remove the solvent when performed properly (never hurts to give it an extra 5 minutes, either). Naturally, one is going to remove the receiver drier or suction accumulator from the system...

 

 

I see. So when you use the solvent with the machine, it is totally out of the system. I was told that the solvent left behind will mix with the oil and be fine.

 

There was a time period where we could no longer get the pancake filter or the in-line permanent filter. We just replaced what was necessary and cleaned what we could. That is basically what i did the second time around. I used brake clean to clean the lines and evaporators. I replaced the condenser because of all the metal in it.

 

It pisses me off that I have done thing a certain way for years without any problems, and then I try something different thinking that I will be doing a better job and it backfires.

[cbriggs]

I used that solvent once too. Same deal, pain in the butt, smells like crap, and smell doent go away for days. Went back to using brake clean, seems to work ok, but i am fighting with a 93 e sd motorhome a/c system right now for contamination, and cant seem to get it clean.....

[Jim Warman]

From what I can see/prove the solvent is purged from the system... From memory (ours is the Cliplight Flushworks) - the flush process should be performed for 15 minutes. The purge procedure should be performed for 30 minutes. This appears to be more than adequate for removing all the solvent from the system.

 

Once you set them machine up for the flush or purge, you can leave it semi-attended while you do other things. (I don't really like the idea of "unattended" for some stuff).

 

What spurred us into getting the machine was that Ford started denying condensers... At one point, there was a TSB for SuperDuties that covered the pooched desicant bags that allowed for replacing the condeser if a flush machine wasn't available - you can't find that TSB any more.

[Keith Browning]

At one point, there was a TSB for SuperDuties that covered the pooched desicant bags that allowed for replacing the condeser if a flush machine wasn't available - you can't find that TSB any more.

TSB 08-13-5 supersedes TSB 06-17-12 only to update the part list. I don't recall the TSB ever "allowed" for the replacement of anything other than the compressor, accumulator/drier and the orifice tube which you are specifically directed to replace. My dealership does not have an A/C flusher and probably never will due to the cost of the machine and the fact that we simply don't see many A/C failures require the use of of one to justify the investment. When we come across one of these failures it has always included a pooched compressor because the owners either didn't realize there was a problem until the A/C completely quit. My manager calls for approval to perform a complete system replacement.

 

Oh, I attached the TSB for ya Jim so ya can find it.

[Jim Warman]

I don't have any problem finding THAT TSB... However, at one point I DID find an authority for changing the condenser. I recall this quite well since the truck that I changed the condenser on was the one I lowered on my hoist with the door open..

 

Did you know that an aluminum ladder with a plastic top step can cause over $1600 damage to a crew cab Super Duty? It makes an amazing jack stand.

 

But, now that you mention it, the passage I recall may have been in a version of the online WSM. I wonder if I could coax the warranty clerk into searching for the RO hard copy????