Pajero io A/C bearing pump DIY

Going in dirt, mud, muddy pool of water and normal wear can make the air conditioning bearing noisy. To replace the bearing I have made a couple of puller to able me to do the work while the A/C unit is still on the car. I wanted to make it practical, cheap and reliable. Yes it is easier to remove the complete A/C pump and do the work on the bench but the cost of new gas (over $200) make these puller worth doing.

EDIT, you can make these tool or you can rent them from me. $55 freight included in Australia with tracking, + $100 deposit fully refunded when the tools comes back. Freight with tracking is about $15. 

I have cut a thick plate of metal, drill 3 holes to match the one on the front plate of the A/C unit

 

I have made a bigger hole in the center to fit a grinded nut in the middle

 

Nut fitted

 

Nut welded

 

Finished tool

 

Tool on a spare front A/C plate

 

This is the second puller to remove the pulley, finished, done with the same metal plate. 

I welded the outside bolt to fit perfectly around the pulley, no gap.

 

Now, at this satge it was not tested on the car. Here we go !!

 

First I removed the center 10 mm nut. As the all lot was moving around I put a long screw driver to hold it in place

 

Installing the my new tool. Before I fitted a longer 10 mm bolt, for the center bolt of my puller to push on it. Do not use the original one as the more thread you have on the better, you do not want to damage the thread.

 

Tighting the center bolt and holding the tool at the same time.

 

Plate out :)  they are washer spacer in it, do not loose them, check if they are not on the end of the A/C unit.

 

Removing the circlips

 

The circlips

 

Installing the other puller

 

Coming out:)

 

Pulley out

 

Removing the bearing, big socket on top of the bearing, and wack...don't be shy ! The first 5 mm can come out while the pully is on a flat piece of timber. I have a press at work but it is not needed here. 

 

Finishing to remove the bearing

 

Bearing out

 

Installing the new bearing

 

Try to put it in as straight as possible, just be gentle while pushing it in, and keep checking that it is straight.

 

Check that it is fully in (small gap here so not fully in !) , the noise when hammer it in will change once fully in location

 

punching around the bearing to hold it in a bit better

 

Punching done

 

Putting it back in was my concern, but since the bearing is fitted on an aluminium shaft I thought that it shouldn't be too hard. I used a hammer with my hand on the radiator side to not hit the radiator. Very easy !

 

Circlips back in, eye on the end of the screw driver

 

Plate back in, tight the 10 mm bolt using the long screw driver to hold it it place.

 

Done :) It took me a while to work out how to get this bearing out, then about 2 hours to do the tools. Maybe a good hour to do the work (taking pictures !). I also removed the fan, the A/C belt, the bottom hose and fitted new coolant. Removing the radiator could be worth doing as well (lots more room then). I had the metal plate on the side, I just bought a few bolt and a $30 bearing. I alway get bearing made in Japan when I can. And next time I have to replace this bearing, that will be very easy !

Happy io