So I finally got my AC to fail while the “in-cabin” volt meter was connected to the compressor wire. Confirmed the compressor wasn’t engaging on command. A tap on the clutch with a piece of wood and it instantly engaged and cooled. 245,000-ish miles on the car.

Can somebody lead me to a photo of a properly installed bread clip? Any favorite adhesive?

Thank you.

I used three evenly-spaced zip ties on my '98 V70 about three years ago. Still works just fine.

Any waterproof glue will do the job. I would not suggest plastic bread clips, instead use some thin sheet metal that you can cut and fold to the proper thickness. You would like a gap of about .010, you are probably over .040 and the magnetic clutch cannot deliver enough energy to pull the clutch.

Here is another 'solution':

https://www.matthewsvolvosite.com/forums/viewtopic.php?f=9&t=77585

But I don't like it because it will probably fry the compressor after the clutch gap gets around .050

Picture abound, just search for Volvo bread clip
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Keeping it running is better than buying new

Thanks Klaus. I measured about .037” gap so yeah it’s about that time. I’ll try to scrounge up some sheet metal in the .025 range to bring me back closer to .010.

I’m with you - not too crazy about cranking up the voltage to get it to engage. I’m not sure about the condition of that 13 year old winding.

I found some sheetmetal sheets at ACE hardware, 8X10. I cut off a strip, folded it once and perfect!

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Keeping it running is better than buying new

Oh I have some scrap pieces of sheet metal around here.... somewhere. If I could just remember where. It’s still a disaster after the move back to GA.

Do the shims need to be cut in any certain way? Like do they have to straddle a fastener or anything? Or can they just be cut square? I’m hoping to be able to slip them in from the top side and not have to pull the wheel and access plate.

I love how I have to log in now every time I want to post a response.

It's been a few years since I last shimmed a Volvo AC compressor clutch but IIRC I settled in on using washers. After finding the appropriate size and thickness, cut a slot in them. Need three. If you're good you can get them to slip over the body of the rubber bits like an E-clip. Which makes me wonder, why didn't I use E-clip in the first place...

But you get the picture. Wedge screwdriver in, fill gap with whatever bits you have (hopefully all same thickness), hope they stay.

Thanks for your response.

I opted to cut the shims out of some ~.020" Galvenized sheet metal I found in the basement. Reduced the gap from ~.037 to ~.017. I didn't want to risk shimming too much and having it drag. I cut them out such that they had narrow "ears" that I crimped over on top in a way that holds them in place while resisting any centrifugally induced departure. I hope. I'll check in a few days and see how many are still in place. It may be quite a while before I achieve the operating conditions at which it previously failed.

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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (STILL not road worthy!)