A/C Bracket broken, lost both belts
 

So, I looked at my 944. I wanna cry lol. It looks like somehow when I started the car, the bracket holding the A/C compressor (I think) broke, and the compressor is hanging off. The belt and the PS belt also are AWOL. I'm not sure if this affected the alternator... I'm still trying to figure out how it all goes together. :(
http://forums.pelicanparts.com/uploa...1342029142.jpg
http://forums.pelicanparts.com/uploa...1342029166.jpg
http://forums.pelicanparts.com/uploa...1342029185.jpg
http://forums.pelicanparts.com/uploa...1342029201.jpg
What do I need to do? I can't tell if the A/C compressor is damaged or not. :( It looks like some metal part on the top of the compressor is sheared off, or something. What bracket will I need? In the pictures if you see anything else broken please tell me :eek: :confused: :(

The bolts that mount the ac compressor to the bracket, have been known to shear off. The bracket also houses the alternator. You deffinately need a new compressor, or you could take this opportunity to delete it, by getting a non-ac alternator bracket. The adjustment rod is also broken. :(

To get at everything,
Take airbox off,
Take alternator off (2 bolts)
Take bracket off (4 bolts)

Non AC Bracket
944-603-134-02
$166 on Pelican

Unfortunately in this case instead of the bolts braking, the compressor housing broke. I think the reason is.... When adjusting the ac/alternator tensioner, the ac compressor bolts should be loose. If they are not, the compressor is basically bolted in place, and strain is put on it, in whichever direction it's moved by the rod.
Only after the belt is tightened and adjusted, can the compressor bolts be torqued.

As it just so happens, I have an alternator/air-con bracket from my '83 that I've been trying to get rid of FOREVER. :p If you need a new one, how does $30 plus shipping sound?

Here's the part I am talking about.

But it's impossible to tell from those photos whether you need it.. Something similar happened to me while I was on the freeway, driving home from Detroit. I had to pull into a cul de sac and do a patch repair at 2am because my battery wasn't recharging anymore. :o Not fun.

Anyway, the middle picture looks like your tensioning strut broke maybe, in which case the compressor would drop and indeed throw your belt off. Basically, from the LH side of the car, looking toward the rear, the motor sits in the middle, and a big aluminum bracket is fastened by four bolts onto the block.

This bracket supports your alternator, and the compressor bolts into the bottom of the alternator (if I remember correctly). So it could be that a bolt holding your compressor to the bottom of your alternator sheered off, which incidentally was my problem. The chances of the alternator bracket breaking are pretty slim. Or, like I said, it could be the tensioning strut, which braces your compressor at the bottom against the bottom front of the block, broke.

This all sounds very confusing, now that I re-read it. Hope it helps a bit..

Okay, so it's not possible to have a shop weld/repair anything in that situation? About that bracket, would it fit on my '86 without problems? What is the adjustment rod and what is the tensioning strut? Also, the bracket that holds the A/C compressor and the alternator is one and the same then?

Correct, they are held by the same bracket. With the air box out of the way, it should be very easy to see whether or not said bracket is intact.

The adjustment rod and tensioning strut are one in the same. Different strokes for different folks. Different names for different dames...

Further than that, I'm afraid I have no real knowledge. :confused: Good luck.

I agree a bit hard to visualize, hope this helps...

http://forums.pelicanparts.com/uploa...1342035205.jpg

A picture is worth a thousand words.
The orange dot is where the tensioner strut mounts to on the compressor.
The green and purple lines are bolts that mount the ac compressor to the bracket
The red and blue lines are the bolts for the alternator

The ear on your ac compressor (the one that takes the green bolt) is broken.
How's the green bolt ear on the bracket?

You can also see the tensioning strut rod end, sheared and still attached to the compressor. (orange dot)

I have a bracket off an 83, no charge, just shipping. let me know.

I doubt the bracket is broken. He just needs to get new mounting hardware, lay under it, and put it all back together.

83 brackets will not fit 86 cars... Ask me how I know.

Wow that really helped a lot. Thanks so much for the support guys. I would really prefer to keep my A/C system working, since it was already converted to R-134a EDIT: Wouldn't an early bracket not fit since the later models have a different alternator?

Wow, just look at the amount of help and support coming!
So happy to continue to experience this support base over the years.

Gawernator you'll soon be up and running:)

I hope so. I have until Friday to get it fixed, missing work in the US Navy is /not/ fun :(

Diagrams of your AC/Alternator system,hope it will help.http://forums.pelicanparts.com/uploa...1342039032.jpg
http://forums.pelicanparts.com/uploa...1342039074.jpg
GL

Hang in there bro, you gotta lot of people rooting for ya!

After talking with my dad. I think what I'm going to end up doing for now is removing the compressor, I'll lose the refrigerant but R-134a is a lot cheaper than the freon I bought for 60$/lb lol. Get a shorter belt to bypass the compressor. I think I can drive that way until I have more time/money to fix the A/C system. Also replace the power steering belt.

Quick thinking and good short term solution to get ya back on the road!

Thanks a lot for the diagrams and images. Very useful

If you delete your A/C compressor you typically install a different alternator bracket. This bracket repositions the alternator where the A/C compressor was allowing you to use the tension strut (which is broken on your car) to adjust the belt tension. You can't just delete the compressor and put a smaller belt on there (as far as I know) because there's no way to adjust the belt tension.

If your long term plan is to retain your A/C, then I wouldn't bother with a temporary A/C delete set up. Once you find out exactly what's broken and needs to be replaced, post and update. I have at least one spare compressor and mounting bracket collecting dust in my garage but I'm across the country so it's not going to get to you in time.

I know a guy in Tucson with a ton of parts, and he knows a few guys in CA with tons of parts so I'm sure you can get what you need quick and cheaply. send me an email if you need those contacts.

I got the airbox off, and jacked the car up. Here are some photos of what I am seeing: http://forums.pelicanparts.com/uploa...1342050797.jpg
http://forums.pelicanparts.com/uploa...1342050813.jpg
http://forums.pelicanparts.com/uploa...1342050828.jpg
http://forums.pelicanparts.com/uploa...1342050850.jpg

I think the bracket is intact. It seems that the compressor is okay but the top mounting part is sheared off. Do I really need to buy a whole new compressor or could the broken mount part be welded back together? I know I will need a new tensioning strut. I'm not sure if I am missing any mounting hardware or not.

Looks like one of your compressor mounting bolts is gone. You'll want to check the threads on the other one to make sure they're still usable.

welding that tab back onto the compressor (provided that you still have the tab) is probably possible, but if I were you I would not bother unless you know a welder who is going to hook you up for cheap...but even then it depend on the break. if it's a clean break and in a place that is accessible, your welder may be confident that he can get it back in the exact same location. if he doesn't you may have a real headache trying to get the compressor back into the bracket.

On the other hand, a used compressor is always a gamble but I'm sure there are quite a few sitting in people's garage like mine who will let you have it cheap of for nothing. Of course, you also have to factor the cost of the recharge of the system but that won't be keeping you off the road.

I personally don't use the A/C so I'd delete it, but that's me.

If you do decide to go for the welding, I'd probably remove the mounting bracket and take it with you so your welder can make sure the two pieces fit properly.

hopefully someone will chime in near you with a spare compressor laying around. Might try contacting some of the Spec944, NASA, SCCA boys near you (maybe a thread search). I bet they have a few compressors collecting dust.

I have a complete A/C setup out of an '88 924S that I'm going to remove. Includes all brackets that you might need, the compressor, and hoses! How's that! Not cheap though, removing this crap is painful.

Thanks for your advice dangerous. And also thanks for the offer but what I need is a new belt, the tensioner strut, and probably another compressor and the missing bolt.

That is exactly what happened to me in Virginia at night travelling back to New York from Florida many moons ago. The ear from the compressor sheared off. I used 2 clothes hangers to literally tie the compressor up. It held all the way back to New York. Of course I ditched the PS belt, and travelled without a/c. As for a temp fix, I was able to fashion bracketry out of 2 old school general motors alternator adjustment brackets using another mounting ear on the compressor. Your compressor is probably still functional. Mine was. That shade-tree old school bracket held on for years. When the compressor clutch finally quit I replaced the whole compressor itself, but it functioned without issue for a good 6 years or so.

That sounds like exactly the fix I need to save me from buying a new compressor. I just figured out the missing ear is gone, so nothing to re attach. Could a shop fabricate something to hold it in place? Or am I doomed to go broke on a new compressor heh

where in CA are you? email me at eddie119@yahoo.com and I'll give you a name and number where you can get a compressor cheap (maybe free if he's in a good mood).

I sent a message.

Okay, one more hurdle. I got all the bolts holding the compressor off but didn't notice the wire connected to it. I finally managed to get the screw off without stripping it, but there's still another wire that is hard wired in. Do I need to just cut it? How will I reconnect the replacement? I thought maybe it unplugs at the other end but the wire just goes all the way and disappears into the firewall. :confused:
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http://forums.pelicanparts.com/uploa...1342062833.jpg

The aft bolt is a standard m8 x 55.
The one that you still have is a m10 x 1,25 x 50, but from the picture, the threads look to be mangled.

As far as the tensioning strut goes, check to see if it's the RH, or LH threaded rod end that broke. You should be able to find a metric rod end (hardware store) if it's the one with the RH thread. Buying a whole OEM rod is not cheap. Even used. At least I couldn't find one when I needed one. Mind you, in Western Canada we don't have 944's at auto wreckers.

It's the right hand side that is broken, that connects to the compressor. I can buy just the part that broke off, don't have to replace the whole strut?! And I will double check the bolt threads, I looked up close and they actually looked fine to me, but was dirty. Maybe that's just reflecting ugly in the photo, I will look again. Thanks for the bolt sizes, I was going to run to NAPA tomorrow and get the missing hardware. My uncle is a manager at an auto parts store, hopefully I can get a compressor from there with that family discount at a great price, or I will call Parts Heaven in CA. Hopefully I can have the car in running shape by Friday sundown. :S

Also, any ideas on that electrical cable? I'm clueless

http://forums.pelicanparts.com/uploa...1342081049.jpg

Man, am I a nice guy :D, I just went outside and took a picture.
There's a plastic sleeve that hides a blade connection. Mine's a 86 NA also, so it should be the same on yours. It looks factory since it has a vw/audi logo on it.
I can take this opportunity to show off my freshly cleaned bracket, and block. http://forums.pelicanparts.com/support/smileys/wat3.gif

I didnt fabricate anything, which I'm sure can be done. I used 2 of those slotted alternator adjustment arms on another mounting ear. Worked fine until the clutch went many years later...

And i have a compressor and bracket from a '87 available as well.
My car was 134 before i removed the system. It worked great but not worthwhile in a race car.

Might have a look at this:

Cheap DIY A/C delete bracket

Parts Heaven got me a compressor for $150, tensioning strut for $25, and the belt for $18. Only missing that one bolt so I'll run down to NAPA/Home Depot and get one. Parts will be here tomorrow. Since I'm using r134 will I need to use the o rings from my old compressor and put them in the new one?

Good post!

Always use new orings
What part of ca. are you in?
Jerry

East bay Area, 45 minutes or so East of San Francisco. Brentwood.

Why can't you just use the ac bracket that is there?

same thing just happened to my 84.

No, chances are the replacement compressor will not come with O-rings for the hose connections. You can pick up an A/C O-ring kit of assorted sizes for ~$10 at autozone or advanced (whichever), but O-rings are only replaced to make sure that the oil that might be on them doesn't mix with the new oil and cause them to deteriorate during a refrigerant swap. There aren't special R-134a O-rings.

It is important, however, to determine if the compressor comes pre-charged with oil inside. If it has mineral oil, it needs to be swapped.

You'll lose your ac charge but the compressor can mount upsidedown to keep the belt tight.
I can ship a belt tensioner or two Monday if you need one , $21 shipped for one or $36 for two?