in my case there was a ~.040" shim washer. It seems I just took out the bolt in the middle of the plate in front of the clutch. I took the washer out and then bolted it back on. You might have to dig it out with a pick or screwdriver if it stays in the hole. I can't really remember the arrangement but it was pretty easy to do from what I recall.

 

Shouldn't the clutch lock up with the key forward and A/C on?

 

You are correct.
I just went out and checked my '04, and it does the same thing - whether the dash A/C control is ON or OFF.

I have monitored 0906 and it definitely goes false when I hear the clutch cycle OFF. It must be a command byte from the PCM.

I checked PID 1101 Bit(A:0) and it goes true when I turn the dash A/C 'ON' and false when I turn it 'OFF'. They must be in series. But I don't have a good way to check/verify the pressure switch readings.

 

that I'm not sure of since the pcm controls the ac relay.

maybe it won't do it if it knows the engine isn't running. I think if you have forscan you can make it do a self test with the engine off and it should close the clutch.

 

Took off the plate and all there was was a 1/32" shim. So now I'm at about .030" air gap. Guess if this isn't my issue I will have to replace the clutch.

 

Took it for a good long drive with an air gap of approx. .030" and A/C did not kick off and ran the entire time. When I had it all apart there was only the 1 washer so as it wears more I will need to eventually replace the clutch. I will update if it starts failing again. Thanks for the help.