Clutch Disc: Service and Repair

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.

2. NOTICE: If the parts are to be reused, index-mark the clutch disc and plate assembly to the flywheel. Failure to install the clutch disc and plate assembly to the flywheel in the original position may result in a clutch system vibration.

NOTICE: Loosen the bolts evenly to prevent damage to the clutch disc and plate assembly.

Remove the 6 clutch disc and plate assembly bolts by loosening them 1 turn at a time using the tightening sequence, then remove the clutch disc and plate assembly.
- Discard the clutch disc and plate assembly bolts.


Installation

1. Inspect the flywheel.





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

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


3. NOTICE: If installing the original clutch disc and plate assembly, align it using the index-marks made during removal or a clutch system vibration can occur.

NOTE: Always install new clutch disc and plate assembly bolts.

Using the Clutch Aligner, position the clutch disc and plate assembly on the flywheel using the index-marks made during removal, install the 6 new clutch disc and plate assembly bolts turning them until they contact the clutch housing surface.
- Turn the bolts 1 turn at a time until the clutch disc and plate assembly is fully secured. Tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 47 Nm (35 lb-ft).

- Stage 2: Tighten 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.

5. Bleed the clutch hydraulic system.

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