AC compressor pulley removal problems

Tiny
OH.EIGHT.GL550
  • MEMBER
  • 2008 MERCEDES BENZ GL450
  • 6.2L
  • V8
  • AWD
  • AUTOMATIC
  • 80,000 MILES
Hello. Very hopeful and grateful for advise on my car.
the serpentine belt broke, after replacing, it failed a week later. I noted then that the ac compressor pulley had a break in it, at the belt edge surface of the pulley.

Tried everything to get the single bolt holding the pulley on the compressor, with the compressor still in place.

long story short, the pulley broke to pieces in the process and the bolt subsequently broke off, leaving the threaded part flush with the pulley itself. Now I have a bearing with no pulley and a broken bolt keeping me from replacing the entire pulley.
With the fan and shroud and many top radiator /grill/ect. Removed to give access space, How do I get the broken bolt out along with the rest of this pulley bearing, and just slide on and secure the new one?
do I have to drill it out?
do I have to remove the compressor itself, then monkey with it?
drilling will destroy the threads I imagine?
either from the front, by taking out the radiator that's still in place
or
from the underside, removing the compressor to work on the broken bolt?

if radiator, looks like it has fixed lines on driver side lower?
if the compressor to remove, how to do so without loosing the freon in the system?

Please please please help me. What seemed right there in my face, sorta easy to fix, has become me taking the whole grill, top frame, fan assembly. Ect. Off AND still, cant get a single solitary bolt to come out.

I am stuck and immobile.
please enlighten me on how to do something.
Monday, March 27th, 2017 AT 11:25 AM

3 Replies

Tiny
WRENCHTECH
  • MECHANIC
  • 20,761 POSTS
I am afraid I do not have good news. These clutches are not generally repairable in the field. You are looking at replacing the whole compressor. In order to do that you also need recovery equipment and knowledge of how to balance the oil in the system. These pulleys are pressed together using special tools to precise measurements done at the factory.
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Monday, March 27th, 2017 AT 1:04 PM
Tiny
JOE IANNIELLO
  • MEMBER
  • 14 POSTS
I have the same issue with my 08 MB GL450. AC compressor pulley destroyed itself. I have access to a vacum system and hoses. Besides the replacement of the compressor, how do I determine what other parts need to be replaced? Thx
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Tuesday, September 3rd, 2024 AT 12:45 PM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 48,363 POSTS
If the compressor came apart internally it will spread metal and seal material throughout the system so it will need to be flushed and the expansion valve replaced. Can you tell if there is debris inside the refrigerant tubes? Here is a video to help with the job and how to change out the compressor and expansion valve.

https://youtu.be/4EqdrBVb0sY?si=tqE2yNp1wekpSNq3

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Tuesday, September 3rd, 2024 AT 3:36 PM

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