A/C stopped working on my 2000 excursion 7.3. I checked for leaks and there were none, system still has refrigerant in it. Found the ac clutch on compressor broken in two pieces, don't know how that would happen. I removed old clutch, cleaned out a bunch of dirt and gummed up material from the pulley and installed the new clutch and shim. Started the vehicle with the climate control off and the engine made a labouring sound. Looked at the ac compressor and found it was turning slowly even though the ax switch was off. Even saw a few sparks come from the pulley and clutch. Turned the ac switch on and everything worked normally. Engine sounded fine clutch and pulley turning fine.
Could the clutch relay be bad? Causing it to be energized and try to turn even though the ac switch is off?
thanks

 

Did you check the gap on the clutch? You might need another shim