Ford A/C :: Clutch Smoked - Huge Stinky Cloud Of Blue Smoke Blowing Out From Behind The Truck


Jul 12, 2013

First some background. The vehicle is a 2003 Expedition with rear AC. The 5.4L engine has been replaced with a 4BT Cummins (DD since 2010), but the AC system is not altered-- other than the compressor being mounted to a different engine. The intercooler is in front of the condenser, which hurts efficiency of the AC system, but it seems to work fine in our climate.

My AC system quit cooling one day, and the problem was a hole in one of the low-side tubes from rubbing on the turbo-to-intercooler tube. I repaired this by aluminum brazing. The system held 120 psi on nitrogen for one hour. So I pumped it down overnight to 27 inches of Hg and made an appointment with the AC shop to get it recharged. I could not get an appointment for several weeks, so I continued to drive it with no AC, thinking it should be no problem since there is no pressure in the system.

I was on a road trip when all of a sudden, there was a huge stinky cloud of blue smoke billowing out from behind the truck. I pulled over and the AC clutch and pulley was smoking hot. I shut it down and cooled it off slowly with squirts from a water bottle.

So my clutch is shot but I'm not sure what caused it to fry. Is there a typical mechanical failure where the friction material can be chewed up by the pulley-hub? Or is it possible that somehow the controller commanded the clutch to engage without pressure in the system?

I think it would be prudent to replace the compressor, since there may be some bearing or housing damage from the clutch failure, so that is in the plan. I have read that when ever the system is open, the drier should be changed too. I want to do this right rather than do it again on another day.

One concern I have is that if when the clutch was failing and it managed to turn the compressor-- could there be pieces of compressor in the tube runs that I need to clean out? Other than a visual inspection of the open tube ends, is there another test or things to look for?

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Then behind me was a HUGE cloud of smoke behind me. I mean really, it covered up the whole street. It was 10 PM, so I couldn't really tell what color it was, but it seemed to be white... So I turned off my car. Checked the engine, no smoke from the engine. I started it up again, and instead to revving to about 2000 rpm at start up like it always does, it only went to about 1000, and more smoke was flushed out the exhaust.

I was close to home, and with no 24-hour mechanic shop around me, I drove home. As I drove home, I had quite a bit of smoke trail behind me which scared me through out the whole 2 minutes of driving. I got home, and I checked the exhaust again, but there was no more smoke. However, a burning smell lingered around the exhaust.

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Today I started it and got a huge cloud of gray smoke out the back. Smoke continued while idling. Shut it off, got a family member to look at it (and make a video of it for future record). Basically on startup it lets out of a big puff of smoke (worse than my old V8 truck with leaky stem seals), then smokes lightly as it idles. Revved the engine and another puff came out, and the smoking did not stop. At this point I called up my dealer and wound up having it towed in as after about 3-5 minutes of running it was still smoking, as I'm under the impression burning synthetic oil is very bad for the emissions control system. Before leaving I let it cool back off, checked the oil and found it about halfway to 2/3rds between full and add on level ground. I did not let it warm all the way up to see what would happen over concern for damage.

Car is sitting at the dealer now, the manager said he'd try to see if they could get to it tomorrow (do have an appointment for Thursday); probably feel bad after the paint fiasco with the last one. Engine ran fine, seemed to be getting good fuel economy this tank, no CELS. I get that 1qt/1000 miles from break down/very minor burning is normal, but not this much smoke and nearly half a quart in 300 probably is not.

I'm also preparing for this to be difficult to pin down as first hand experience tells me oil burning can be a pain sometimes to troubleshoot, but my 91 Camry with 225k on it doesn't smoke like this, and typically valve stem seal seepage (which would be unacceptable though not serious) goes away quickly and presents much later in engine life. Not cold at all and had an oil burning smell to it for sure, but anyone have any normal expectations for what it could be? My 2012 2GR had 34k on it with zero oil use, burning or issues. If they say nothing my plan is to show them a video, and see what they say.

Pretty frustrated as I was liking this car more than my 2012; felt like it ran a little better, got a little better gas mileage, and road/drove a bit nicer too (probably the newer tires). Also had run into zero issues, whereas in the same span of ownership my 2012 already had one paint repair, a recall, and a brake light switch. Just had an oil change in June too at the dealer, verified the level was fine when I got it back, no leaks either.

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