2015-2025 Expedition & Navigator A/C Compressor: Noises, TSBs, and Evaporator Issues

Symptoms of a Failing A/C Compressor

A failing A/C compressor in a Ford Expedition or Lincoln Navigator will make itself known through several distinct symptoms. Paying attention to these signs can help you diagnose the problem before it causes a complete system failure.

A/C Blows Warm or Merely Cool Air

This is the most common symptom. If the compressor is weak or has failed, it cannot adequately pressurize the refrigerant to start the cooling process. The air from your vents may be slightly cooler than the outside air but will not be cold. This can also be a sign of low refrigerant, which could be caused by a leak in the compressor or elsewhere in the system.

Loud Grinding, Whining, or Squealing Noises

Unusual noises from the engine bay when the A/C is turned on are a major red flag. A grinding or rattling sound often indicates failing internal bearings. A loud squeal can point to a slipping serpentine belt, which may be caused by a compressor that is beginning to seize. If the compressor's internal components fail, they can send metal debris throughout the entire A/C system, leading to a much more expensive repair.

A/C Compressor Clutch Does Not Engage

The compressor has a clutch on its pulley that engages and disengages to cycle the compressor on and off. You should hear a distinct 'click' when you turn on the A/C, and you can visually see the outer plate of the pulley start spinning with the belt. If the clutch does not engage, it could be due to a failed clutch coil, a blown fuse, low refrigerant pressure (which prevents engagement as a safety measure), or a faulty compressor.

Visible Refrigerant Leak

The compressor has several seals that can fail over time, leading to leaks. A/C refrigerant contains a special oil to lubricate the compressor. If you see a greasy, oily residue on the body of the compressor, it's a sign of a leak. Technicians often add a UV dye to the system to make finding these leaks easier with a blacklight.

Known Issues, TSBs, and Recalls

For the 2015-2025 Ford Expedition and Lincoln Navigator, several known issues can be mistaken for a faulty A/C compressor. Always check for these possibilities before replacing the compressor itself.

TSB: A/C Evaporator Freezing Up (Poor Cooling/Low Airflow)

Many owners of 2018-2020 Expedition and Navigator models (among other Fords) have experienced poor A/C performance or a sudden loss of airflow, especially on hot days. This is often caused by the A/C evaporator core freezing into a block of ice. The root cause is frequently a faulty evaporator temperature sensor that gives incorrect readings. Ford issued TSB 21-2250 and the updated TSB 22-2089 to address this. The fix involves replacing the sensor, which is a labor-intensive job as it is located deep within the dashboard.

Recall: Front Blower Motor Fire Risk (2015-2017 Models)

Customer Program: Contaminated Refrigerant (2018 Models)

A specific batch of 2018 Expedition and Navigator vehicles built between January and early February 2018 were subject to Customer Satisfaction Program 20N08 (also referenced as 18N01). These vehicles may have been filled with contaminated R-1234yf refrigerant from the factory. This could cause a lack of A/C cooling. The program extended the warranty on A/C components and required dealers to use special equipment to evacuate the system and replace the compressor and other parts if contamination was found.

TSB: Water Leaking into Passenger Footwell (2018-2020 Models)

TSB 20-2170 addresses an issue where the A/C evaporator drain tube could allow condensation to leak into the right front passenger floor area. While not a direct compressor failure, this water leak has been theorized by Ford to be a contributing factor in another recall (24S06) for inadvertent seat belt pretensioner deployment due to potential corrosion. The fix involves installing a simple elbow on the drain tube.

The Critical Refrigerant Question: R134a vs. R1234yf

During this vehicle's production run, manufacturers transitioned from R134a refrigerant to the more environmentally friendly but more expensive R1234yf. The 2018 model year appears to be the primary transition point for the Expedition and Navigator.

Before purchasing a compressor or servicing the system, you MUST verify which refrigerant your vehicle uses. This information is found on a sticker under the hood, typically on the radiator support or a strut tower.

Buying a Used A/C Compressor

A used OEM compressor can be a cost-effective and reliable alternative to expensive new parts, especially when compared to cheap, new aftermarket units which can have questionable quality. When buying used, careful inspection is key.

• Verify Part Numbers: Match the part number from your old compressor to the used one. The provided OEM part numbers are a good starting point, but physical confirmation is best.
• Check the Pulley and Clutch: The pulley should spin freely and smoothly by hand with no grinding or roughness. The clutch plate on the front should be intact and not show signs of extreme heat or scoring.
• Inspect for Leaks: Look for oily residue around the seals and where the two halves of the compressor body meet. A clean, dry compressor is a good sign.
• Ensure Ports are Capped: A reputable seller will cap the inlet and outlet ports to prevent moisture and debris from entering the compressor during storage and shipping. A compressor that has been left open to the elements is likely contaminated and should be avoided.
• Confirm Refrigerant Type: Ensure the donor vehicle used the same type of refrigerant (R134a or R1234yf) as your vehicle.

Replacement Overview & Difficulty

Replacing the A/C compressor is a difficult job best left to professionals or experienced DIY mechanics. The primary challenge is the need for specialized equipment to safely and legally recover the refrigerant from the system before starting work and to properly vacuum and recharge the system afterward.

• Difficulty: 4 out of 5
• Key Steps: Refrigerant recovery, serpentine belt removal, disconnecting electrical connectors and refrigerant lines, unbolting the old compressor, installing the new one, and then vacuuming and recharging the system.
• Required System Flush: If the old compressor failed internally, the entire system must be flushed to remove metal debris. You must also replace the receiver/drier (or accumulator) and the orifice tube (or expansion valve) to ensure the new compressor isn't damaged and to validate its warranty.

Cost Comparison

Note: Labor costs do not include the price of refrigerant or other necessary parts like a receiver/drier or system flush.

Frequently Asked Questions (FAQ)