Hope this helps
Removal (4WD F150 Models With S.R.O.D)
Raise and support vehicle. Drain transmission and/or transfer case. Disconnect 4WD indicator switch at transfer case. Disconnect back-up light switch wire at transmission.
Mark position of front and rear drive shaft. Disconnect rear drive shaft from transfer case and wire aside. Remove speedometer cable from transfer case. Remove retaining clips and shift rod from transfer case control lever and shift lever.
Disconnect vent hose from transfer case. Remove shift lever-to-transmission turret screws. Remove shift lever from turret. Support transmission with jack and remove transmission housing-to-engine rear bracket.
Raise transmission to remove weight from crossmember. Disconnect gusset-to-support and remove gusset on left side. Remove transmission support plate bolts.
Remove support plate-to-crossmember bolts. Remove support plate and remove right gusset. Remove crossmember. Remove transfer case heat shield.
Support transfer case. Remove transfer case-to-transmission adapter bolts. Slide transfer case off output shaft and lower transfer case from vehicle. Remove gasket between transfer case and adapter.
Support transmission with a jack. Remove transmission-to-flywheel housing bolts. Move transmission rearward until input shaft clears flywheel housing. Remove transmission.
To install transmission, reverse removal procedure. Install guide pins in flywheel housing lower mounting bolt holes. Move transmission on guide pins until input shaft splines enter clutch hub splines and case is against flywheel housing.
With transmission removed, remove starter and clutch housing. Mark flywheel and clutch cover for reassembly. Loosen clutch cover bolts evenly until spring tension is released. Remove clutch assembly from vehicle.
To install, clean flywheel surface and reverse removal procedure. Apply grease to release lever fingers and lever pivot ball. Tighten cover bolts evenly and alternately. Reinstall transmission.
NOTE:Needle roller bearing and adaptor is used as clutch pilot bearing on all models. Bearing and adaptor are a single unit and cannot be serviced separately.
With transmission removed, remove clutch pressure plate and disc. Using impact slide hammer and puller (T59L-100B and T58L-101-A), remove pilot bearing.
Using pilot bearing replacer and clutch aligner (T74P-7137-A and T71P-7137-H), install pilot bearing with seal facing transmission. Reinstall clutch pressure plate, disc and transmission.
CLUTCH HOUSING ALIGNMENT
Remove transmission and flywheel housing. Reinstall flywheel housing and rear engine plate without transmission. Tighten mounting bolts.
Mount dial indicator on bolt using "C" clamp. Position stem of dial indicator on face of clutch housing. Push crankshaft rearward to remove any end play.
Set dial indicator to zero. Rotate flywheel and watch indicator reading. Face runout should not exceed.010" (.254 mm). Bore runout should not exceed.015" (.381 mm).
If runout is excessive, remove clutch housing and original dowels from rear face of engine block. Install offset dowels in same size pairs. Install clutch housing and shim between flywheel housing and engine if face alignment is necessary.
Remount dial indicator and check alignment. If bore alignment is excessive and face alignment is accurate, shim flywheel housing to limit of face misalignment. Check bore alignment, if not within limit, replace housing.
Fig. 1: Mounting Clutch and Linkage Mark flywheel and clutch cover for reassembly.
CLUTCH PEDAL FREE TRAVEL
The amount of pedal movement from full stop to point where release bearing contacts clutch fingers is pedal free travel. Specified travel is 3/4-1 1/2" (19-38 mm). If incorrect, adjust linkage.
Remove retracting spring. Loosen both lock nuts on rod. Position bullet end of rod tight against clutch release lever. Push rod tight against arm to eliminate all free play.
Insert a.135" (3.4 mm) spacer or gauge between lock nut and bullet. Tighten nut against spacer with all free play eliminated.
Tighten second lock nut against first, finger tight. Remove spacer and tighten lock nuts together. This will give specified pedal free play.
If not to specification, repeat adjustment until correct free play is obtained.
Monday, November 17th, 2008 AT 4:45 PM