CLUTCH DISC, FLYWHEEL, PILOT BEARING & PRESSURE PLATE
NOTE:Replace clutch disc and pressure plate as an assembly. Replace pilot bearing only if damaged.
CAUTION:Do not use cleaners with a petroleum base, or immerse pressure plate in solvent.
Disconnect negative battery cable. Disconnect clutch master cylinder push rod. Raise and support vehicle. Remove starter. Disconnect clutch slave cylinder hydraulic line by pressing White retainer bushing with Disconnect Tool (T88T-70522-A) while pulling on line. See Fig. 3 .
On 4WD vehicles, remove transfer case. See TRANSFER CASE . On all models, remove transmission. See TRANSMISSION . Check pressure plate finger height variations before removing pressure plate. If finger height variations exist, replace pressure plate. Place reference mark on pressure plate and flywheel for reassembly reference. Loosen pressure plate-to-flywheel bolts evenly until springs are expanded. Remove pressure plate and clutch disc.
Remove all but 2 flywheel bolts. Loosen last 2 bolts. Install 2 flywheel bolts in threaded holes in flywheel. Using puller, remove flywheel, and then pilot bearing.
Inspect clutch pressure plate diaphragm fingers for wear. Inspect clutch plate for oil or grease saturation, worn or loose facings, warpage, loose rivets at hub and broken springs. Also, inspect for wear or rust on splines.
Using slide caliper, measure rivet head depth. Minimum rivet head depth is .012" (0.3 mm). Using dial indicator, check clutch plate runout. Maximum clutch plate runout is .028" (0.7 mm). Inspect flywheel for cracks, heat damage, wear and scoring. Machine flywheel if scored or worn. Using dial indicator, measure flywheel runout. Maximum flywheel runout is .003" (0.1 mm) on Explorer, or .008" (0.2 mm) on all others.
Check crankshaft for misalignment and looseness. Check pilot bearing needle rollers for scoring, discoloration, wear, breakage and inadequate grease. Check rear main seal for leakage. Inspect pressure plate for burn marks, scores, flatness and ridges. Install NEW clutch plate on transmission input shaft, and ensure clutch plate slides freely.
Clean pressure plate and flywheel surface with alcohol-based solvent. Pilot bearing is prelubed and does not require additional lubrication. Install pilot bearing with seal facing transmission. Using driver, install pilot bearing. Adjust pressure plate. See CLUTCH PRESSURE PLATE (OFF-VEHICLE) under ADJUSTMENTS.
Using Clutch Alignment Shaft (T74P-7137-K), position clutch disc onto flywheel. Position pressure plate assembly onto flywheel. Align pressure plate and clutch disc with reference mark, and install retaining bolts.
Apply Threadlock/Sealer (EOAZ-19554-AA) to flywheel bolt threads. Tighten bolts evenly in a crisscross sequence to specification. See TORQUE SPECIFICATIONS . See Fig. 4 . Remove clutch input shaft or clutch aligner. To complete installation, reverse removal procedure. Tighten bolts to specification.
Fig. 4: Pressure Plate Tightening Sequence
Courtesy of FORD MOTOR CO.
CLUTCH MASTER CYLINDER & RESERVOIR
Pry retainer bushing and push rod off clutch pedal pin. Disconnect master cylinder push rod from clutch pedal. Remove Clutch Pedal Position (CPP) switch. See CLUTCH PEDAL POSITION SWITCH .
Remove clutch master cylinder reservoir. Raise and support vehicle. Disconnect clutch slave cylinder hydraulic line by pressing White retainer bushing with Disconnect Tool (T88T-70522-A) while pulling on line. See Fig. 3 . Plug line to prevent leakage.
Disconnect line from mounting clips. Lower vehicle. Rotate master cylinder 45 degrees clockwise, and remove clutch master cylinder.
Inspect master cylinder for weak spring, damage to reservoir components and damaged cups. Also, check master cylinder for scored piston.
When installing NEW master cylinder, bench bleed master cylinder. See BENCH BLEEDING (MASTER CYLINDER) under BLEEDING. To install, reverse removal procedure. Clean all rubber components with DOT 3 brake fluid. Replace clutch master cylinder push rod retainer bushing if worn or damaged.
Ensure retainer and push rod are installed onto clutch pedal pin with flange portion of bushing facing away from pedal blade of clutch pedal. Bleed hydraulic system. See ON-VEHICLE BLEEDING under BLEEDING. Depress clutch pedal at least 10 times to check for proper release and smooth operation.
CLUTCH SLAVE CYLINDER & RELEASE BEARING
CAUTION:Clutch release bearing is prelubed and should not be cleaned with solvent. Clutch release hub and bearing are replaced as an assembly. Do not disassemble for inspection or replacement.
Disconnect clutch slave cylinder hydraulic line by pressing White retainer bushing with Disconnect Tool (T88T-70522-A) while pulling on line. See Fig. 3 . Plug line to prevent leakage. Raise and support vehicle. Remove transmission. See TRANSMISSION .
Remove 2 internal (concentric) clutch slave cylinder bolts. Remove concentric clutch. Push clutch release hub and bearing against spring. Remove retainer ring. Remove clutch release hub, bearing and spring. See Fig. 5 .
Check internal (concentric) clutch slave cylinder for leakage. Replace slave cylinder as necessary. Also, check slave cylinder for weak spring, worn or damaged piston and worn or damaged boot. Rotate outer race while applying pressure. If bearing rotation is rough, replace clutch release hub and bearing. Check for any surface scoring or burrs inhibiting sliding motion of clutch release hub and bearing.
Prior to installation, lubricate bearing bore and bearing carrier with multipurpose grease. On clutch release hub, polish any scoring or burrs with fine grade emery paper. To complete installation, reverse removal procedure. Bleed hydraulic system. See ON-VEHICLE BLEEDING under BLEEDING. Tighten bolts to specification.
Disconnect negative battery cable. Raise and support vehicle. Remove skid plate, if equipped. Remove vibration damper from transfer case, if equipped. If disassembling transfer case, drain fluid.
On manual shift transfer cases, disconnect HO2S connector. On electronic shift transfer cases, remove wire connector from feed wire harness at rear of transfer case.
On all models, mark drive shafts for reassembly reference. Disconnect drive shafts from transfer case output shaft yokes. Wire drive shafts aside. Remove VSS connector, nut and sensor. Disconnect vent hose from shift control selector lever and housing.
On all models, support transfer case with a jack. Remove transmission exhaust heat shield and wiring harness. Remove bolts attaching transfer case to extension housing. Slide transfer case off transmission output shaft. Lower transfer case from vehicle. Remove gasket from transfer case and transmission extension housing.
Clean gasket surfaces and install NEW transfer case-to-extension housing gasket. To complete installation, reverse removal procedure. Tighten transfer case-to-extension housing bolts in sequence to specification. See TORQUE SPECIFICATIONS . See Fig. 2 .
Lubricate vehicle speed sensor "O" ring with ATF. Tighten remaining bolts to specifications. Fill transfer case with appropriate lubricant. See appropriate SERVICING article.
Fig. 2: Transfer Case-To-Extension Housing Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
Disconnect negative battery cable. Shift transmission into Neutral. Remove boot assembly-to-floor bolts. Remove boot from gearshift lever assembly.
Remove gearshift lever retaining bolt. Remove gearshift lever, ball and boot assembly. Raise and support vehicle. Disconnect HO2S connectors, VSS connector and back-up light switch connector. If transmission disassembly is required, drain fluid. Mark drive shaft and rear axle flange for installation reference.
Disconnect drive shaft at rear drive axle flange. Remove drive shaft. Cap transmission extension housing to prevent lubricant spillage.
Using Disconnect Tool (T88T-70522-A), disconnect clutch slave cylinder hydraulic line by pressing White retainer bushing while pulling on line. See Fig. 3 . Cap end of line to prevent fluid leakage and contamination. Remove starter electrical connectors, and remove starter.
On 4WD models, remove transfer case. See TRANSFER CASE . Position transmission jack under transmission. Remove rear engine support insulator-to-crossmember nuts and bolts. Remove crossmember. Remove right transmission-to-exhaust bracket bolt, and reposition exhaust bracket. Remove exhaust inlet crossover pipe. Lower transmission enough to gain access to transmission-to-engine bolts. Remove transmission-to-engine bolts.
Slide transmission rearward to separate bellhousing from dowel pins on rear of engine block. When spline on input shaft clears clutch disc, lower transmission from vehicle.
Ensure mating surfaces and locating dowels are clean and free of burrs. Ensure transmission input shaft splines are clean. Place transmission onto transmission jack, and position under vehicle.
Raise transmission into position and start input shaft into clutch disc. Align splines on input shaft with splines on clutch disc. Move transmission forward until case seats onto locating dowels.
Install transmission-to-engine block bolts. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill transmission with appropriate lubricant. See appropriate SERVICING article. Bleed clutch hydraulic system. See ON-VEHICLE BLEEDING under BLEEDING.
Saturday, December 13th, 2008 AT 2:25 PM