how to install a clutch
11-18-2006, 03:34 PM
#22
4th Gear Member
Join Date: Jan 2006
Location: Fredericksburg, Virginia
Posts: 1,175
RE: how to install a clutch
good luck with it bro.
i just bought my spec clutch stage 1. I would like to install it myself but i have no time and..definetly not the skill as of yet haha.
i just bought my spec clutch stage 1. I would like to install it myself but i have no time and..definetly not the skill as of yet haha.
11-18-2006, 03:44 PM
#23
3rd Gear Member
Join Date: Sep 2006
Location:
Posts: 760
RE: how to install a clutch
Disc and Pressure Plate
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number
Clutch Aligner T74P-7137-K
Removal
CAUTION: Under no circumstances should a prying instrument such as a screwdriver or a pry bar be used to install or remove the clutch release lever cable (7535) from clutch and brake pedal pivot shaft (7506) as damage to cable may occur.
Lift clutch pedal (7519) to its uppermost position to disengage clutch and brake pedal pivot shaft . Push clutch and brake pedal pivot shaft forward, unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward. Refer to Clutch Release Cable, Removal and Installation, Section 08-02.
Raise vehicle on a hoist. Refer to Section 00-02.
Remove clutch release lever dust shield (7513) .
Disconnect clutch release lever cable from clutch release lever.
Remove retaining clip and remove clutch release lever cable from flywheel housing (6392) .
Remove starter motor (11002) from flywheel housing .
Remove bolts that secure engine rear plate to front lower part of flywheel housing .
Remove transmission. Refer to Section 07-03. Remove bolts that retain flywheel housing to cylinder block (6010) . Move flywheel housing back far enough to clear clutch pressure plate (7563) and remove.
Remove clutch release lever from flywheel housing by pulling it through window in flywheel housing until retainer spring is disengaged from pivot.
Remove clutch release hub and bearing (7548) from clutch release lever.
If same clutch pressure plate is to be installed, mark clutch pressure plate and flywheel (6375) so that clutch pressure plate can be installed in its original position. Loosen six clutch pressure plate retaining bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate . Remove clutch pressure plate and clutch disc (7550) from flywheel .
Installation
CAUTION: The clutch pedal must be lifted to disengage the adjusting mechanism during clutch release lever cable installation. Failure to do so will result in damage to the self-adjuster mechanism.
Position clutch disc and clutch pressure plate assembly on flywheel . Three flywheel clutch pressure plate dowels on flywheel must be properly aligned with clutch pressure plate . Bent, damaged or missing dowels must be replaced. Start clutch pressure plate retaining bolts but do not tighten. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
Align clutch disc using Clutch Aligner T74P-7137-K inserted in pilot bearing (7600) . To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight. Then tighten clutch pressure plate bolts to 40-50 Nm (30-37 lb-ft) for 3.8L or 24-32 Nm (18-24 lb-ft) for 5.0L. Remove alignment tool.
Apply a light film of Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B to:
Outside diameter of transmission main drive gear bearing retainer (7050) .
Clutch release lever and anti-rattle spring where they contact clutch release hub and bearing .
Clutch release lever stud (7B602), mating release lever pocket and cable ball pocket.
Fill grease groove of clutch release hub and bearing with same grease. Clean all excess grease from inside bore of the clutch release hub and bearing . Otherwise, excess grease will be forced onto spline by transmission main drive gear bearing retainer , and will contaminate clutch disc .
Install clutch release hub and bearing to clutch release lever.
Install clutch release shaft (7515) and clutch release hub and bearing to flywheel housing .
Inspect flywheel housing dowel holes for misalignment and wear.
Make certain that flywheel housing and cylinder block mounting surfaces are clean and that flywheel housing to block dowels (6397) are in good condition. Bent, damaged or missing flywheel housing to block dowels must be replaced.
Install flywheel housing to cylinder block . Tighten bolts to 38-52 Nm (28-38 lb-ft) for 3.8L or 52-74 Nm (38-55 lb-ft) for 5.0L.
Install transmission to flywheel housing. Refer to Section 07-03.
Install bolts that secure engine rear plate to front lower part of flywheel housing .
Connect clutch release lever cable to flywheel housing and connect retaining clip.
Connect clutch release lever cable to clutch release lever. Install clutch release lever dust shield .
Install starter motor .
Lower vehicle.
Install clutch release lever cable by lifting clutch pedal to disengage clutch and brake pedal pivot shaft . Then, push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft . Cycle clutch pedal several times to adjust clutch release lever cable . Refer to Section 08-02.
Clutch Disc and Pressure Plate
Item Part Number Description
1 6397 (2 Req'd) Flywheel Housing to Block Dowel
2 — Rear Face of Block and Flywheel (Part of 6010)
3 6397 Flywheel-to-Clutch Pressure Plate Dowel (3 Req'd)
4 7548 Clutch Release Hub and Bearing
5 7515 Clutch Release Lever
6 7600 (Install with Seal Toward Rear of Vehicle) Pilot Bearing
7 7550 Clutch Disc
8 7563 Clutch Pressure Plate
9 7B602 Clutch Release Lever Stud
10 34794-S2 Washer
11 N606063-S2
57664-S2 Bolt (6 Req'd) (3.8L)
Bolt (6 Req'd) (5.0L)
12 6392 Flywheel Housing
13 7050 Main Drive Gear Bearing Retainer
14 55981-S36M Bolt
15 7513 (Installed After Cable Assy) Clutch Release Lever Dust Shield
16 N807508-S2
N602549-S2 Screw and Washer Assy (6 Req'd) (3.8L)
Screw and Washer Assy (6 Req'd) (5.0L)
A — Tighten to:
38-52 Nm (28-38 Lb-Ft) (3.8L)
52-74 Nm (38-55 Lb-Ft) (5.0L)
B — Tighten to:
40-50 Nm (30-37 Lb-Ft) (3.8L)
24-32 Nm (18-24 Lb-Ft) (5.0L)
--------------------------------------------------------------------------------
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number
Clutch Aligner T74P-7137-K
Removal
CAUTION: Under no circumstances should a prying instrument such as a screwdriver or a pry bar be used to install or remove the clutch release lever cable (7535) from clutch and brake pedal pivot shaft (7506) as damage to cable may occur.
Lift clutch pedal (7519) to its uppermost position to disengage clutch and brake pedal pivot shaft . Push clutch and brake pedal pivot shaft forward, unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward. Refer to Clutch Release Cable, Removal and Installation, Section 08-02.
Raise vehicle on a hoist. Refer to Section 00-02.
Remove clutch release lever dust shield (7513) .
Disconnect clutch release lever cable from clutch release lever.
Remove retaining clip and remove clutch release lever cable from flywheel housing (6392) .
Remove starter motor (11002) from flywheel housing .
Remove bolts that secure engine rear plate to front lower part of flywheel housing .
Remove transmission. Refer to Section 07-03. Remove bolts that retain flywheel housing to cylinder block (6010) . Move flywheel housing back far enough to clear clutch pressure plate (7563) and remove.
Remove clutch release lever from flywheel housing by pulling it through window in flywheel housing until retainer spring is disengaged from pivot.
Remove clutch release hub and bearing (7548) from clutch release lever.
If same clutch pressure plate is to be installed, mark clutch pressure plate and flywheel (6375) so that clutch pressure plate can be installed in its original position. Loosen six clutch pressure plate retaining bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate . Remove clutch pressure plate and clutch disc (7550) from flywheel .
Installation
CAUTION: The clutch pedal must be lifted to disengage the adjusting mechanism during clutch release lever cable installation. Failure to do so will result in damage to the self-adjuster mechanism.
Position clutch disc and clutch pressure plate assembly on flywheel . Three flywheel clutch pressure plate dowels on flywheel must be properly aligned with clutch pressure plate . Bent, damaged or missing dowels must be replaced. Start clutch pressure plate retaining bolts but do not tighten. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
Align clutch disc using Clutch Aligner T74P-7137-K inserted in pilot bearing (7600) . To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight. Then tighten clutch pressure plate bolts to 40-50 Nm (30-37 lb-ft) for 3.8L or 24-32 Nm (18-24 lb-ft) for 5.0L. Remove alignment tool.
Apply a light film of Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B to:
Outside diameter of transmission main drive gear bearing retainer (7050) .
Clutch release lever and anti-rattle spring where they contact clutch release hub and bearing .
Clutch release lever stud (7B602), mating release lever pocket and cable ball pocket.
Fill grease groove of clutch release hub and bearing with same grease. Clean all excess grease from inside bore of the clutch release hub and bearing . Otherwise, excess grease will be forced onto spline by transmission main drive gear bearing retainer , and will contaminate clutch disc .
Install clutch release hub and bearing to clutch release lever.
Install clutch release shaft (7515) and clutch release hub and bearing to flywheel housing .
Inspect flywheel housing dowel holes for misalignment and wear.
Make certain that flywheel housing and cylinder block mounting surfaces are clean and that flywheel housing to block dowels (6397) are in good condition. Bent, damaged or missing flywheel housing to block dowels must be replaced.
Install flywheel housing to cylinder block . Tighten bolts to 38-52 Nm (28-38 lb-ft) for 3.8L or 52-74 Nm (38-55 lb-ft) for 5.0L.
Install transmission to flywheel housing. Refer to Section 07-03.
Install bolts that secure engine rear plate to front lower part of flywheel housing .
Connect clutch release lever cable to flywheel housing and connect retaining clip.
Connect clutch release lever cable to clutch release lever. Install clutch release lever dust shield .
Install starter motor .
Lower vehicle.
Install clutch release lever cable by lifting clutch pedal to disengage clutch and brake pedal pivot shaft . Then, push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft . Cycle clutch pedal several times to adjust clutch release lever cable . Refer to Section 08-02.
Clutch Disc and Pressure Plate
Item Part Number Description
1 6397 (2 Req'd) Flywheel Housing to Block Dowel
2 — Rear Face of Block and Flywheel (Part of 6010)
3 6397 Flywheel-to-Clutch Pressure Plate Dowel (3 Req'd)
4 7548 Clutch Release Hub and Bearing
5 7515 Clutch Release Lever
6 7600 (Install with Seal Toward Rear of Vehicle) Pilot Bearing
7 7550 Clutch Disc
8 7563 Clutch Pressure Plate
9 7B602 Clutch Release Lever Stud
10 34794-S2 Washer
11 N606063-S2
57664-S2 Bolt (6 Req'd) (3.8L)
Bolt (6 Req'd) (5.0L)
12 6392 Flywheel Housing
13 7050 Main Drive Gear Bearing Retainer
14 55981-S36M Bolt
15 7513 (Installed After Cable Assy) Clutch Release Lever Dust Shield
16 N807508-S2
N602549-S2 Screw and Washer Assy (6 Req'd) (3.8L)
Screw and Washer Assy (6 Req'd) (5.0L)
A — Tighten to:
38-52 Nm (28-38 Lb-Ft) (3.8L)
52-74 Nm (38-55 Lb-Ft) (5.0L)
B — Tighten to:
40-50 Nm (30-37 Lb-Ft) (3.8L)
24-32 Nm (18-24 Lb-Ft) (5.0L)
--------------------------------------------------------------------------------
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