As promised! This procedure worked great on my car, as well on one of my coworkers car. Both were 2003 with same type compressors. Please note that compressor shown in the pictures - also from 2003 3.0 which was replaced by the local shop for the same reason. I was to late to advise owner on this repair.

Steps:
1. Remove radiator fan and shroud
2. Remove splash pan
3. Remove AC belt
4. Unscrew torx bolt on the front of the compressor clutch and remove clutch plate. It comes out easily. Be careful not lo lose thin spacer washer / washers. Some may stay in the clutch plate and some may stick to the end of the shaft.
5.Remove snap ring that hold the clutch hub / bearing and pry it off. Worked off carefully using two large flat screwdrivers or small pry bars. Needs little extra effort here, but it will come out.
6.Pry off thermal fuse cover on the clutch coil. It will break in pieces. No worries here.
7. With exacto knife, scrape insulation from coil wires right next to the crimp connectors and solder piece of wire between them. Ignore / break / remove thermal fuse. You can safely leave without it.
8. Verify that circuit is restored using multimeter, or run DIS diagnostic.
9. Seal area with silicone sealer to prevent corrosion.
10. Re assemble compressor clutch.
11. Re-install belt, fan and splash pan
12. Enjoy working AC.

Attached Images

   

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2012 X5 x35i My new toy
2005 X5 4.4 Her's (Retrofitted Servotronic Steering Rack)
2003 X5 3.0 Mine (Retrofitted Servotronic Steering Rack and Heated Steering Wheel)
2001 M5 Son's car
2000 540i 6sp Sports pkg, supercharged. Son's car (Sold)
2001 530i (Sold)
1999 528i (Sold)
1975 2002 (Sold)