Removal and Replacement

Clutch Disc and Pressure Plate - 5.4L

















Removal

WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

1. Remove the transmission. For additional information, refer to Manual Transaxle/Transmission - TR6060 Removal.

2. NOTICE: Loosen the bolts evenly to prevent damage to the pressure plate.

NOTE: If the pressure plate is to be reused, index-mark the pressure plate to the flywheel.

Remove the 6 pressure plate bolts by loosening them 1 to 3 turns at a time using the tightening sequence, then remove the pressure plate and the clutch disc.

- Discard the pressure plate bolts.

Installation

1. Inspect the flywheel. For additional information, refer to Flywheel Runout Check in Manual Transaxle/Transmission and Clutch - General Information Flywheel Runout Check.





2. NOTICE: Clutch Aligner 308-599, must be used or clutch damage may occur.

NOTE: If installing the original plate and disc assembly, align it using the index marks made during removal.

Using the Clutch Aligner, align the entrapped clutch disc in the pressure plate assembly.

3. NOTE: Always install new pressure plate bolts.

Using the Clutch Aligner, position the clutch disc pressure plate assembly on the flywheel, install the 6 new pressure plate bolts turning them until they contact the clutch housing surface. Tighten the bolts in the sequence shown.

1. Turn the bolts 1-2 turns at a time until the clutch is fully secured.

2. Tighten to 47 Nm (35 lb-ft).

3. Tighten each bolt an additional 60 degrees.





4. NOTICE: Apply a small amount of PTFE lubricant to the splines of the clutch hub. This will make sure that the clutch will not bind on the transmission input shaft, making sure of correct clutch operation. Using lubricant other than Motorcraft PTFE lubricant may cause clutch chatter.

NOTE: Before securing the transmission to the engine, connect the clutch hydraulic line to the slave cylinder.

Install the transmission. For additional information, refer to Manual Transaxle/Transmission - TR6060 Installation.

5. Bleed the clutch hydraulic system. For additional information, refer to Manual Transaxle/Transmission and Clutch - General Information Service and Repair.

6. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.