How to Install an A/C Compressor Bypass Pulley in a 1996 V8 4.6L Ford Thunderbird

In 1996, Ford decided to cease production of the Thunderbird Super Coupe, offering an optional sport package equipped with a 4.6-liter eight-cylinder engine in its place. The A/C compressor on the 4.6-liter engine is located on the lower, passenger side of the engine. A failed A/C compressor is a hefty repair bill, so aftermarket part suppliers created an A/C bypass pulley. The bypass pulley is a direct replacement for the A/C compressor, allowing the compressor to be removed without affecting the belt routing or the direction of rotation for other engine accessories.

Instructions

Compressor Removal

1

Drive the vehicle to a repair shop to have any remaining refrigerant evacuated from the A/C system before proceeding.

2

Park the vehicle on a level surface and set the parking brake. Lift the vehicle hood and support it with the hood prop rod.

3

Lift the front of the vehicle with the floor jack and place the jack stands under the front frame rails. Lower the floor jack until the vehicle rests securely on the jack stands. Remove the floor jack.

4

Sketch the belt routing on a piece of paper and set it aside for later use. Place a -inch breaker bar into the square hole on the belt tensioner. Rotate the tensioner arm clockwise and remove the belt from around the alternator pulley. Release the tensioner to its normal resting position and remove the belt from the engine.

5

Lay down under the vehicle. Remove the splash shield for the passenger side of the engine, if equipped. Loosen all three A/C compressor bolts with the socket and ratchet. Gain a firm hold on the A/C compressor and remove all three bolts from the compressor. Lower the A/C compressor from the engine bay and discard the A/C compressor mounting bolts.

Bypass Pulley Installation

6

Hold the bypass pulley to the engine block and line up the mounting holes with the compressor bolt holes in the block. Install the new bolts included with the bypass pulley and tighten them with the socket and ratchet.

7

Inspect the serpentine belt for any cracks, glazing or fraying and replace as necessary. Route the serpentine belt around the crankshaft pulley, belt tensioner and other engine accessories according to the sketch made previously. Hold the belt tight at the alternator pulley and install the breaker bar into the square hole on the belt tensioner.

8

Rotate the belt tensioner arm clockwise while simultaneously pulling on the belt until it slips over the alternator pulley. Slowly release the tensioner arm to apply tension to the belt. Remove the breaker bar from the belt tensioner and inspect the belt to ensure it is properly seated on each pulley.

9

Install the passenger side splash shield (if equipped). Lift the car off the jack stands and remove the jack stands from under the vehicle. Lower the vehicle to the ground and remove the floor jack. Remove the A/C lines, accumulator and evaporator core as you see fit.