Clutch

Clutch Disc And Pressure Plate

Special Tools:

Special Tool(s)

Removal
1. Remove the transmission.





2. Index-mark the clutch pressure plate and the flywheel, if reinstalling these parts.





3. Remove the bolts, the clutch pressure plate, and the clutch disc.
4. Inspect the transmission input shaft pilot bearing:
- for misalignment and looseness in the crankshaft (gasoline engine) or flywheel (diesel engine).
- needle rollers for scoring, discoloration, wear, and broken rollers.
- seal for damage and lubricant leakage.
- Install a new transmission input shaft pilot bearing if any of these conditions are present.

Installation

1. CAUTION: Sometimes, when removing the transmission, the input shaft will remove a considerable amount of lubricant from the transmission input shaft pilot bearing.

Lubricate the transmission input shaft pilot bearing, as necessary.
- Use High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-MICl98-A.





2. CAUTION: When installing the original clutch pressure plate on 5.4L and 6.8L applications, reset the wear indicator before installing the clutch pressure plate on the flywheel.

Reset the wear indicator.
1 Using a suitable press and adapter, press downward on the fingers until the adjusting ring moves freely.
2 Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3 Release the pressure on the fingers. The adjusting ring will now stay in the reset position.





3. Position the clutch disc on the flywheel and the special tool in pilot bearing to align the clutch disc.
- Use tool 308-090 for 5-speed applications, and tool 308-421 for 6-speed applications.
- The 5.4L/6.8L engines accept a 1 1/4" input shaft.
- The 7.3L engines accept a 1 3/8" input shaft.





4. NOTE: Align the index marks if installing the original clutch pressure plate and flywheel.

Install the clutch pressure plate.
1 Position the clutch pressure plate on the dowels.
- The diesel engine flywheel has two dowels. The gasoline engine flywheel has three dowels.
2 Using the special tool, align the clutch disc and the pressure plate.
3 Install the bolts and tighten in a star pattern sequence.
4 Remove the special tool.
5. Install the transmission.
6. Test the system for normal operation.