This is my sob story - In about '99, the compressor froze. Bummer! I took it a local reputable A/C shop, and they told me that the '97 models had a higher capacity pump, and that would prevent this failure in the future. I think the only thing they had to modify was the plug end of the harness.
This set-up worked better than the original.
On my way to Southern Arizona last fall, this pump froze, too.
Another guy down here tells me the components , or design?, of these were "built to eat themselves", and he could replace it with a newer design built from different materials.
I really want my A/C, but refuse to waste that much $$$ again.
Is there any truth to this "new design"??

 

I've not heard of a cannibalistic compressors for these trucks but I'm no AC expert. We have a forum just for HVAC issues here on FTE, These guys are very knowledgeable and willing to help.
https://www.ford-trucks.com/forums/forum61/

In my limited experiences with compressors going bad usually happen because of small leaks that require adding a can of refrigerant every year or two with out adding a little oil or.... because of over-charging the system. Some of the 'fix-a-leak' additives can cause failures too.

 

They normally freeze up from improper maintenance. If some tire shop ac expert replaces components in the system and doesn't clean it out good, replace the filter drier, orifice tube and properly evac and recharge it then it will most likely not last long.
It may not even have locked up. Did you check it? The clutch is kinda common to fail on these year models in my opinion. I've been discovering that certain brand of belts from aftermarket stores are the right listing for it but too tight and wear the clutch bearings out. They cause most of the other pulley bearings to fail too. I got burned twice last year by one place that I bought belts from. They fit but were too tight on the tensioner.

I know it's rediculously expensive getting ac work done these days. It's a total scam by garages if you ask me. That's why I work for myself now. Home acs aren't much different. I got several quotes to put air in my house last year and the lowest was 9000 dollars. I did it myself for 900!. I used the exact same brand new parts they were going to also. Go figure.
A car AC shouldn't cost more than 500 to replace the compressor. When I first got my 97 powerstroke I had to replace it and it was about 250 dollars worth of parts and refrigerant. When I did it professionally most people were getting a bill for over a thousand though. Blame the flat rate pay system for the high price and probably for the system not lasting very long.

 

Update - Local Ford dealer offered to diagnose for free, so, sure, knock yourself out. The tech pulled out some kind of fine screen (about 2" long), and it is clean. Says that indicates only the front half of the compressor froze and it didn't contaminate the system. Just put a compressor/clutch unit on and I'm good to go.
Well, then they call to say my fan clutch is garbage because it doesn't pull enough air at idle, and that causes an overpressure situation. Bad news. I'm pretty sure it has never pulled "enough air" at idle for the A/C, and I bought this truck new. A/C has always been weak when stuck in traffic. However, the clutch seems to work normally when the engine needs a little more air - the temp guage never goes higher than mid range.
Dilemma - Pay $400 for another stock fan clutch - that I'm not convinced is any better than what I have - or looking at some sort of semi auto electric booster fan for those idle situations.
I really need some ideas, guys. Sooner would be better!
Thanks-
Jess

Edit - The service manager just called to say he watched the tech STOP the fan with his finger while it was idling. Not something I would have tried!

 

I would get an electric setup.
The fan can be stopped when at idle if it is not hot. (Disclaimer: I would not try stopping it with your finger, just shows your ignorance IMO).
If you have no problems driving or towing (if you do any) then an electric fan would help your idle situation. There are stories on here that once you go electric the A/C is colder than ever. I personally would go all electric if you could. It takes some fab work but you get good results. I plan on this setup eventually myself.

 

That fan clutch is a very common and very very often misdiagnosed problem on the older ford trucks like this. Mine was misdiagnosed a few weeks ago before I baught it. The dealer charged the last owner 300 dollars to recharge the system then when it over pressured and blew out the relief valve they said the compressor was fried and would cost 1500 dollars more to fix. It was only the fan clutch. Mine was turning so slow the other day at idle I could have stopped it with my finger too but I'm not that slow upstairs to try it.

Often the sensing element on the front of it can be blown off and it will work fine again. Not all the time though. If it's covered with dirt or mud real bad then it won't know when your radiator is hot. Try to clean it off first with compressed air but still be prepared to replace it.
Once you do replace it have the charge checked again. It will probably be off from when it was charged with not enough air flow.

 

How to replace a/c compressor on f-250 super dutty (1999, 7.3 L)?

Thanks.