So the bearing in the AC compressor was shot & i replaced it with a kit off of Ebay for $83 bucks which beats out the cost of a new compressor plus the cost of vacuuming & refilling the system.

With a new clutch included then installed, it made a horrible scraping sound which ain't normal. I decided to clean the old clutch, greased it up, then installed it. The metal to metal scraping is less, but still not normal. I hand tightened it very lightly till it was good enough to engage the clutch, then let it sit still when the AC is off.

I will try to get a short video of it to help figure this all out. In the mean time, does anyone have any ideas to remedy this?

 

There is a specified air-gap for the clearance......................I am not sure what the spec for the XJ is, but it should have been included in the kit for the clutch..........................It probably could be looked up in a service manual.............

If it's too close, it rubs when not engaged......................If it's too far, then it won't engage properly, and you'll get slippage and burn up your clutch.....

Sometimes there are little spacer washers included in the kit. They go on the shaft before the clutch shoe......................Sometimes you just press the shoe on far enough for the proper air-gap, and put the lock nut on.

edit: I just looked it up on Identifix for a 1998....................

 

it also states a break-in procedure for a new clutch...................

CLUTCH BREAK-IN
After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off) During this procedure, set the heater-A/C control to the Recirculation Mode, the blower motor switch in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.

 

I put the old clutch back on...


There were spacers on the outside of the old clutch which seemed more like washers. However, they did fit directly on the inside of the clutch & I used one so far. I'll buy a feeler gauge, then add another, then check the specs...