Pressure Plate: Service and Repair

REMOVAL

Special Tool:

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 from clutch and brake pedal pivot shaft because damage to cable may occur.

1. Prop clutch pedal in place.
2. Raise vehicle on a hoist.
3. Remove clutch release lever dust shield.
4. Disconnect clutch release lever cable from clutch release lever.
5. Remove retaining clip and remove clutch release lever cable from flywheel housing.
6. Remove starter motor from flywheel housing.
7. Remove bolts that secure engine rear plate to front lower part of flywheel housing.
8. Remove transmission. Remove bolts that retain flywheel housing to cylinder block. Move flywheel housing back far enough to clear clutch pressure plate and remove.
9. Remove clutch release lever from flywheel housing by pulling it through window in flywheel housing until retainer spring is disengaged from pivot.
10. Remove clutch release hub and bearing from clutch release lever.
11. If same clutch pressure plate is to be installed, mark clutch pressure plate and flywheel so 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 from flywheel.

3.8 L Engine (Part 1 Of 2):

Part 2 Of 2:

4.6 L Engines (Part 1 Of 2):

4.6 L Engine (Part 2 Of 2):

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.

NOTE: The clutch disc must be assembled so FW SIDE or FLYWHEEL SIDE stamped notation is facing toward the engine. The three flywheel-to-clutch pressure plate dowels and the flywheel must be properly aligned with the clutch pressure plate. Bent, damaged or missing dowels must be replaced.

1. 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.
2. Align clutch disc using Clutch Aligner 308-020 (T74P-7137-K) inserted in pilot bearing. 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 27-39 Nm (20-28 ft. lbs.) for 3.8L or 25-33 Nm (19-24 ft. lbs.) for 4.61L (2V) and 4.6L (4V) engines. Remove alignment tool.
3. 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.
^ clutch release lever and anti-rattle spring where they contact clutch release hub and bearing.
^ clutch release lever stud, 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.
4. Install clutch release hub and bearing to clutch release lever.
5. Install clutch release lever and clutch release hub and bearing to flywheel housing.
6. Inspect flywheel housing dowel holes for misalignment and wear.
7. Make certain flywheel housing and cylinder block mounting surfaces are clean and flywheel housing to block dowels are in good condition. Bent, damaged or missing flywheel housing to block dowels must be replaced.
8. For T50D, install flywheel housing to cylinder block. Tighten bolts to 38-52 Nm (28-38 ft. lbs.). Install transmission to flywheel housing.
9. For T45, install transmission and flywheel housing to cylinder block. Tighten bolts to 38-52 Nm (28-38 ft. lbs.).
10. Install bolts that secure engine rear plate to front lower part of flywheel housing.
11. Connect clutch release lever cable to flywheel housing and connect retaining clip.
12. Connect clutch release lever cable to clutch release lever. Install clutch release lever dust shield.
13. Install starter motor.
14. Lower vehicle.
15. Remove prop from clutch pedal. Cycle clutch pedal several times to adjust clutch release lever cable.