A/C rebuild in progress

[Mahlon]

I'm in the process of rebuilding the chassis air conditioner on my 2003 W22 (again), and decided to share my trials & tribulations.

What failed: A/C compressor clutch has no air gap between the pulley and clutch plate. Why this is will be determined later; remedy is to R/R the entire compressor because I lack the tools to repair it. Expansion valve and filter/dryer will be replaced at same time because the new compressor warranty requires it.

All parts being purchased through CarQuest, unless otherwise noted.

A/C compressor: Availability was no problem. Both the A/C Delco p/n (1136519) and the Four Seasons / Murphy p/n (88950) crossed over to an interchangeable part number.

Expansion valve: Again, no problem. AutoZone p/n 157743 interchanges with CompressorWorks p/n 758901, which interchanges with Murray p/n 38901 and probably lots of others.

Filter/dryer: BONK. This appears to be unique to the W22, unfortunately. All of the part numbers except the Workhorse part number (W8000070) on Dale's web site are dead ends. Workhorse (Uptime Parts) is on back order until mid-September (what a great time of the year for THAT), and Victory Climate Systems (the company that swallowed SCS/Frigette, evidently) doesn't sell parts. So if you are in my situation at present, you are stuck with calling around trying to find a unit in a service center parts room.

Along the way I was told by a Workhorse parts tech that GM p/n's 12375979, 12375379, 12546083, and Delco 15-1640 are the correct physical size and have the correct fittings, but don't have the correct bracket configuration (if they have a bracket at all). These should correspond to the unit still shown on Victory's web site here as p/n 054-00139 (note that this is not the same refrigerant fitting configuration shown here on Dale's web site).

Oil type: PAG 150, in case you didn't know.

More to come as I dig into this.

[Good man]

Mahlon,
Thanks so much for being willing to journalize your trials and troubles. The real value of this forum comes from the bank of knowledge which is available for withdrawl at anytime.
Unfortunately, too many people are willing to make withdrawls without ever considering making a deposit for the good of the order.
Best of luck to you in your bold expression of good old self-reliance! ...And keep us posted on your progress.
Jim

[UFO Pilot]

Mahlon

Give these folks a call for Victory Climate Systems parts:

Hal's Auto Care and Truck Repair
2425 Tower Road
Sacramento CA 95825
(916) 485-9215
Mike Schedler


They ordered a new part for me and were great to work with.

[pkmesser]

My filter/dryer was replaced 2 years ago by a local shop, they did not use a Workhorse unit. My paperwork does not give a number for it, and it is not visable on the unit. Whatever it is, it fits, the only thing, it does not have a bubble view glass, which I believe the original did.

[herbc]

I just bought a 2003 Allegro Bay 37DB on Workhorse and before I could even use the thing the compressor went out. My mechanic spent several hours trying to locate the dryer W8000070 and of course I am being charged for that time. I decied o find one myself and found one at the Workhorse dealer but not the same part number. I bought it and sent it to my mechanic who says it will require some piping changes for another 2 hours. I sure wasn't told all of this to begin witn and now the bill is up to $1400. If I had known that I would have deleted the dash AC and just put a pulley on it. Darndest thing is I trust this mechanic. Quite an expense when I have nit even used it.

[DriVer]

Quote:

Originally Posted by herbc Quite an expense when I have nit even used it.

It is indeed frustrating to have to pay for someone else's learning curve.

[mr300ce]

quote: Whatever it is, it fits, the only thing, it does not have a bubble view glass, which I believe the original did.

The old R12 systems used site glass on drier, not on R134a systems.

AND....IMHO.....you are getting ripped-off if the shop/tech is charging for the time it takes to located parts. I have worked in auto repair for 20yrs+ and managed a busy shop for past 7+yrs. We DO NOT charge for finding parts.

Installing a parts that does NOT just drop in will cost more labor to MIF it.

MIF=Make It Fit, used in building airplanes. (B1-B's all 95)

[DriVer]

Quote:

Originally Posted by mr300ce quote: Whatever it is, it fits, the only thing, it does not have a bubble view glass, which I believe the original did. The old R12 systems used site glass on drier, not on R134a systems.

When I put the question to my service center about the bubbles floating past the sight glass he said that it was normal. Therefore having a drier w/o a sight glass could be a blessing!

If you had anything to do with building our B1-Bs. Last sighting of a B1 was at the Warner Robbins Museum.

[Floridakamper]

I had the same compressor issue the original poster had. I had the local WH service center do the job. They also spent most of the day running around trying to match up the dryer. Not on my nickel thankfully. They finally gave up and said they could try and order the correct part but it would tie up my unit for some time or they could put the old dryer back in and just take a longer vacuum on the system before recharging. I told them to use the old dryer and so far it seems to be working well.

[John350]

Another part Number could be 89018424. Do not know anything about it. I think it is for a dryer for a W22 chassis 2003. Let the group know if it works out.
Happy motoring

John
w-22
Allegro Bay Tiffin 2003

[mr300ce]

Quote:

Originally Posted by DriVer When I put the question to my service center about the bubbles floating past the sight glass he said that it was normal. Therefore having a drier w/o a sight glass could be a blessing! If you had anything to do with building our B1-Bs. Last sighting of a B1 was at the Warner Robbins Museum.

Yep, B1-B's. Nuclear bombers. Glad we never had to use them. Reagan had the great idea about them. Build 100 bombers real fast (3yrs). Russians spent a large part of their treasury trying to copy and 'catch up'.

Carry a big stick. Bombers ! Then Russia went broke, and broke up. B1-B retired.

AC problem....you could actually adapt any new drier of approx same size. They all do the same function. They filter, store, and 'dry' the freon. Dry=remove water from the system. Water gets into system whenever the lines are opened.

Inside the drier is a thing called desiccant. It is a bag of crystals that absorbs the water. If the bag breaks open, the crystal get into the system and ruin everything. I've seen the mess many times.

Will kill compressor, plug condensors and evaporators, and plug orifice tubes and expansion valves. Expensive repairs.

Anytime any other parts are changed, warranty of those parts is voided if drier is not replaced too.

All the 'vacuum' time in the world is not gonna prevent the bag from breaking open on an old drier.

I've done 100-200 new AC installs, and 100's of repairs. Getting tired now........retire-ing in 3 more yrs at 62. Fulltime travel, here I come.

[ron55]

I have had mine replaced 3 times compelety at three different workhorse repair centers all because of the clutch clearance, using only workhorse parts, well maybe, at the last spot there was a the largest Napa store I ever saw next door.
The last time in Grand Juction, Co, Bear Automotive Workhorse Repair and they did an excellent job and the air is much cooler than it has ever been. Now I don't even have to run the gen and house air

[herbc]

Quote:

Originally Posted by herbc I just bought a 2003 Allegro Bay 37DB on Workhorse and before I could even use the thing the compressor went out. My mechanic spent several hours trying to locate the dryer W8000070 and of course I am being charged for that time. I decied o find one myself and found one at the Workhorse dealer but not the same part number. I bought it and sent it to my mechanic who says it will require some piping changes for another 2 hours. I sure wasn't told all of this to begin witn and now the bill is up to $1400. If I had known that I would have deleted the dash AC and just put a pulley on it. Darndest thing is I trust this mechanic. Quite an expense when I have nit even used it.

Saga continues. I thought the drier was the main issue. Not! Now it is the expansion valve. According to the work center all drawings for my unit show the wrong valve. Mechanic states he spent 4 hours researching this to no avail.(Not on my ticket, Thank Goodness.) I spent thirty minutes or less with Tiffin, the valve is a Denso, I ordered it and it will be here next Wednesday. Thank you, Tiffin. Problem is the time lost and the RV sitting in an unsafe location. This has been a frustrating experience. Anyone having a similar experience I would recommend contacting Tiffin for correct part numbers.

Herb

[DriVer]

Quote:

Originally Posted by herbc This has been a frustrating experience. Anyone having a similar experience I would recommend contacting Tiffin for correct part numbers.

Herb, Calling the OEM excellent advice.. Just so that you know form this point forward.

AIR CONDITIONING
Workhorse motor home chassis come standard with approximately half of the dash air conditioning components. The components supplied by Workhorse are mounted to the chassis during chassis manufacturing. The remaining components are installed by the body manufacturers due to the multiple interior configurations. The components provided by Workhorse are:

WORKHORSE RESPONSIBILITY
1. Delphi/Harrison compressor used on all motor home chassis.
2. Condenser, mounted in front of the radiator
(has been offered with a pre-charge of 1.5 lbs. of
refrigerant-total system capacity determined by
body manufacturer).
3. High-pressure switch, mounted by the receiver
dryer.
4. Receiver drier mounted to the right hand side of
the condenser.
5. Electric Condenser fan(s) mounted on the
condenser or on the external transmission
cooler, position in front of the condenser,
controlled by the PCM.
6. Compressor discharge hose (shipped loose).
7. Low-pressure switch (shipped loose).
Component supplied by the body manufacturer:

NOT WORKHORSE RESPONSIBILITY
1. A/C and heater controls.
2. All other A/C hoses.
3. Evaporator core.
4. Ducts and vent work.
5. Blower motor.
6. Other switches and wiring.
7. All dash heating components.
8. Heater control valve.
9. Thermostatic expansion valve or orifice tube.

10. Final refrigerant/oil fill and testing.