Took it apart to remove a shim and found it scored and almost a burnt look to the inner part. Also a lot of grease around the shaft, wondering if it's refrigeration oil seeping out, grease from the clutch bearing or just accumulated from the engine bay from years of never being removed. (I keep the engine clean but obviously not inaccessible areas)

 

Also there is only one shim

 

How does the AC work? Mine looked worse than that when I changed it. AC worked when driving but took a break when I stopped at a light. New clutch fixed it. Adding a shim might help too. Have you checked the gap?

 

The gap is at the outer edge of the service limit so I was going to remove one, the only one left. Yes it warms up a bit more than it used to at idle although the clutch stays engaged but I am afraid it might be slipping. AC gets a workout here in the desert, we turn it on around March and turn it off around November.

I think I will pick up a new Motorcraft tomorrow.