Pressure Plate: Service and Repair

Prior to installing throw-out bearing, apply a light film of lithium base lubricant part No. C1AZ-19590-B or equivalent to transmission front bearing retainer outside diameter, the clutch release fork and anti-rattle spring where they contact the release bearing hub and to the throw-out bearing where the bearing contacts the pressure plate release fingers. In addition, fill the throw-out bearing grease groove with the same lubricant. Wipe off all excess lubricant.
1. Lift clutch pedal to its uppermost position to disengage pawl and quadrant. Push quadrant forward, unhook cable from quadrant and allow it to slowly swing rearward.
2. Raise and support vehicle.
3. Remove retainer pin and clevis pin from lower end of bellcrank.
4. Remove retaining clip, then clutch cable from flywheel housing.
5. Remove starter electrical connectors, then starter motor from flywheel housing.
6. Remove transmission.
7. Remove flywheel housing-to-engine attaching bolts, then flywheel housing.
8. Disconnect short cable from release lever by pushing cable and release lever boot approximately 1/2 inch toward release bearing and pull cable rearward through hole in boot.
9. Remove release lever boot from flywheel housing.
10. Remove clutch release lever from housing by pulling it through window in housing until spring is disengaged from pivot.
11. Remove release bearing from release lever.
12. Loosen six pressure plate cover attaching bolts evenly to release spring tension gradually and avoid distorting cover. If same pressure plate and cover is to be installed, mark cover and flywheel so pressure plate can be located in original position.
13. Remove pressure plate and clutch disc from flywheel.
14. Position clutch disc and pressure plate assembly on flywheel. The three dowel pins on flywheel must be properly aligned with pressure plate. Bent, damaged or missing dowel pins must be replaced.
15. Start cover attaching bolts but do not tighten.
16. Align clutch disc using proper alignment tool inserted in pilot bearing. To avoid pressure distortion, alternately tighten bolts a few turns at a time, until seated. Torque pressure plate to 12-24 ft. lbs.
17. Remove alignment tool.
18. Apply light film of long life lubricant part No. C1AZ-19590-BA or equivalent to:
a. Outside diameter of transmission front bearing retainer.
b. Release lever fork and anti-rattle spring where they contact release bearing hub.
c. Release bearing surface that contacts pressure plate release fingers.
d. Release lever ball pivot and mating release lever pocket.
e. Fill grease groove of release bearing hub. Clean all excess grease from inside bore of bearing hub or contamination of clutch disc will occur.
19. Attach clutch release bearing to release lever.
20. Attach release lever and release bearing to flywheel housing.
21. Install release lever boot in housing with hole toward transmission.
22. Install short cable in release lever boot, then into keyhole slot in release lever, by pushing boot toward release bearing.
23. Install flywheel housing to engine block and torque to specification.
24. Install flywheel inspection plate.
25. Connect clutch cable to flywheel housing and connect retaining clip.
26. Place clevis over end fitting of cable, then install clevis pin and retaining pin.
27. Install starter motor, then transmission assembly.
28. Install clutch cable assembly by lifting clutch pedal to disengage pawl and quadrant. Then, push quadrant forward and hook end of cable over rear of quadrant.
29. Cycle clutch pedal several times to adjust cable.