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Old 08-18-2013, 08:22   #1 (permalink)
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2003 E-450 6.8 V10 cuts off/stalls

Hi everyone, I don't own my truck, it's my work vehicle, but has been so good to me that it has converted me to Ford. I'm a mobile 18-wheeler trailer tech and put serious mileage on it on a weekly basis. My problem started when the faceplate of the A/C clutch was seemingly about to shatter (a piece of it was flapping around), so the company bought a new clutch to install. For access, I removed the air filter assembly, radiator fan and shroud, and belt. After a few hours of inventing new curse words, I had the clutch on and everything back together, started the truck and everything worked perfectly... Until 30 seconds later when it turned itself off. It fired right back up, but did it again. And then again. It finally got to a point where it would run at idle, but step on the pedal and try to maintain any steady RPM and it cuts off. If that wasn't bad enough, the A/C clutch spins but doesn't work (even the blower motor quit working). What have I done?? I'm almost positive everything went back the way it should have! The old clutch was so bad off that the bearings were destroyed, could the entire compressor be to blame somehow? I desperately have to get this truck back on the road ASAP. Any help very greatly appreciated!
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Old 08-18-2013, 10:19   #2 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

Is the A/C clutch quitting or the engine? Did you set the gap for the clutch within specs?
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Old 08-18-2013, 10:21   #3 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

Okay, either I was clouded by fatigue or rage (perhaps both), but I foolishly forget to but the back of the air filter intake back on. She's running perfectly now, aside from the AC still not working, which I can honestly live without. Still going to make an attempt to find out why. Keep you posted. I feel both great relief and hugely embarrassed. Thanks all!
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Old 08-18-2013, 10:22   #4 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

Not a problem, we all make mistakes. Thanks for the update.
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Old 08-18-2013, 10:36   #5 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

Thanks Bert. FORDS RULE!!
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Old 08-18-2013, 11:45   #6 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

Update #2: still no action from the blower motor or ac clutch. All fuses and relays are check (as best as I can tell as I only have the owners manual layout). Thoughts?
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Old 08-18-2013, 12:10   #7 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

Here's the diagram for a 2004 and 2002 and for some reason, the 2003 diagrams don't show. The blower doesn't come on either?

| Repair Guides | Heating, Ventilation & Air Conditioning (2004) | Heating, Ventilation & Air Conditioning (2004) | AutoZone.com

| Repair Guides | Heating, Ventilation & Air Conditioning (2002) | Heating, Ventilation & Air Conditioning (2002) | AutoZone.com
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Old 08-18-2013, 12:30   #8 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

Sorry Bert, that just took me to the autozone site (I'm on an iPhone in our shop). No, the blower isn't working at all, in any setting. Never had trouble out of it until now.
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Old 08-18-2013, 15:07   #9 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

It is at Autozone and has all of the diagrams. I'm sure you checked all of the fuses?
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Old 08-18-2013, 17:56   #10 (permalink)
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Re: 2003 E-450 6.8 V10 cuts off/stalls

The problem may not be in the clutch. Even if there's not an interlock between the fan and the compressor, the clutch will be de-energized in w relatively short period of time since there's no air moving across the cooling coil. Try to get the fan running first, then go back to the compressor.
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