Dash Air Compressor Problem

[Rob Robinson]

A week or so ago I noticed my York AC compressor pulley was wobbling so I
pulled it and found that someone had failed to use a proper Woodruff Key.
This resulted in damage to both the compressor's tapered shaft and
receiving pulley/clutch assembly. With the advice of Randy Dupree I was able
to affect what I hope is a permanent fix. This was a process that involved a
lot of 'Machinist Specialist' filing and Hope and a Prayer JB Welding. In
the first place I couldn't find a Woodruff key that would fit the York
shaft. The ones I found were the right thickness but the wrong configuration
for the half-moon AC compressor shaft slot. In addition, the AC compressor
shaft had quite a nick out of it and a smaller one was present on the
Pulley/Clutch corresponding groove. I filed for quite a while until
achieving the correct half moon configuration and then cemented it in the AC
compressor shaft with JB Weld. After letting it set for a couple of days I
filed all the excess and trial fit the pulley..........no dice. The assembly
would bind so some fine tuning was required. It turned out that the Woodruff
key was too tall and after several very careful filings the whole assembly
went together without the clutch and pulley binding. As an aside, on the
final assembly I greased half the tapered shaft with JB weld. I should
mention that I am leaving for the Oshkosh Bluebird Rally on Friday and this
is the reason for the above remedy. Having more time I would have replaced
the unit.

PS. My York requires a NC 5/8" bolt to remove the pulley/clutch assembly.

--
Rob, Sue & Merlin Robinson
94 WLWB


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