1991-1994 CAPRI 1992 MARK VII 1992-1994 TOPAZ 1992-1997 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-1997 MARK VIII 1995-1997 MYSTIQUE
1992-1996 BRONCO 1992-1997 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, RANGER 1993-1997 VILLAGER 1995-1997 WINDSTAR 1997 MOUNTAINEER
A new air conditioning spring lock coupling cleaning procedure has been developed. This procedure is required for a thicker O-ring that has been released for servicing spring lock couplings. These O-rings have a larger cross-sectional diameter for improved sealing. The thicker O-ring is green in color and identifiable only by the part number. These are service only O-rings and will not be used in production.
Clean the Spring Lock Coupling(s) (SLC), if their service is required, and install the new thicker O-rings by referring to the following Service Procedure for details.
Recover refrigerant from the A/C system.
Remove old O-rings using a plastic O-ring tool and discard. Plastic O-ring Service Tools are available from Rotunda in the R-134a/R-12 Port Kit (164R2602) or the O-Ring Pick/Valve Core Removal Tool Kit (164R2604). These items can be ordered by calling 1-800-768-8632 (Mon-Fri, 8AM-5PM EST). When prompted, press choice 2 for dealership supply orders.
Check the female SLC O-ring sealing surface for scratches, corrosion, or debris from deteriorated O-rings. Clean any surface residue from the inside of the couplings by using the following procedure (Steps 4a-4j):
Obtain the following shop equipment and cleaning supplies locally:
3-1/2" length of steel brazing rod
YN-9 (mineral) oil for R-12 systems or YN-12-B (PAG) oil for R-134a systems
Variable speed electric drill
Safety goggles or glasses
Lint free cloth
12" length of natural fiber string (twine or kite string)
Abrasive material - maroon colored 3M "Scotch Brite" pad cut in strips as follows:
Abrasive Strip Dimension
1" X 2"
1" X 2"
1" X 3"
1" X 4"
Fabricate a cleaning tool (Figure 1).
Figure 1 - Article 96-20-8
Determine coupling size and select the appropriate length of abrasive strip from the Step 4a table.
Insert abrasive strip into the cleaning tool (Figure 2).
Figure 2 - Article 96-20-8
Insert completed assembly into drill and tighten chuck securely.
Coat the abrasive strip in appropriate refrigerant oil.
Roll abrasive strip around cleaning tool (Figure 3).
Figure 3 - Article 96-20-8
DO NOT ALLOW THE DRILL SPEED TO EXCEED 1500 RPM AS TOOL SEPARATION MAY OCCUR.
Using a variable speed drill set at a low speed, slowly insert cleaning assembly into the female coupling. Clean using a moderate speed for approximately 1 minute or until surface is clean. Maintain low speed drill rotation while removing the cleaning assembly to prevent axial scratches, which may cause future leaks.
IT IS IMPORTANT TO USE A LINT FREE CLOTH TO PREVENT MATERIAL FIBERS FROM REMAINING ON THE O-RING SEALING SURFACE AND CAUSING FUTURE LEAKS.
Remove all cleaning residue from the coupling using a lint free cloth.
Inspect O-ring sealing surface for grooves. If grooves or scratches cannot be removed, replace the component.
Inspect the male SLC O-ring grooves for scratches, corrosion, or debris from O-ring deterioration. Remove any surface residue from the O-ring grooves by cleaning using the following procedure (Steps 5a-5b):
Loop the 12" length of natural fiber string around SLC and clean O-ring sealing surface (Figure 4).
Figure 4 - Article 96-20-8
Remove all cleaning residue using a lint free cloth.
ONLY USE NEW GREEN O-RINGS. THE USE OF ANY O-RING SEALS OTHER THAN SPECIFIED MAY ALLOW CONNECTION TO LEAK INTERMITTENTLY DURING VEHICLE OPERATION.
Reassemble the SLC by referring to the following procedure (Steps 6a-6e):
Lubricate the new O-ring seal using appropriate refrigerant oil.
Install new O-rings.
Lubricate the inside of the female coupling with the appropriate refrigerant oil.
Install plastic indicator ring into cage opening if indicator ring is to be used.
IF THE PLASTIC INDICATOR RING IS USED, IT WILL SNAP OUT OF THE CAGE OPENING WHEN THE COUPLING IS CONNECTED TO INDICATE ENGAGEMENT. IF THE INDICATOR RING IS NOT USED, CHECK THE COUPLING ENGAGEMENT BY VERIFYING THAT THE GARTER SPRING IS OVER THE FLARED END OF THE FEMALE COUPLING.
Fit female coupling to male coupling and push with a twisting motion until the garter spring snaps over the flared end of the female fitting.
Repeat procedure as necessary for any remaining couplings. Verify seal integrity by leak testing the coupling. If coupling continues to leak, replace the component.