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Clutch Disc and Pressure Plate: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Sometimes, when removing the transmission, the input shaft will remove a considerable amount of lubricant from the transmission input shaft pilot bearing.
  1. Lubricate the transmission input shaft pilot bearing, as necessary.
    • Use Krytox® High-Temperature Grease.
    2. CAUTION: When installing the original clutch pressure plate, reset the wear indicator before installing the clutch pressure plate on the flywheel.
    Fig 1: Rotating Adjusting Ring Counterclockwise
    GF0007147Courtesy of FORD MOTOR CO.
  2. Reset the wear indicator.
    1. Using a suitable press and adapter, press downward on the fingers until the adjusting ring moves freely.
    2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
    3. Release the pressure on the fingers. The adjusting ring will now stay in the reset position.
  3. Position the clutch disc on the flywheel and the clutch alignment tool in the pilot bearing to align the clutch disc.
    • The 5.4L/6.8L engines accept a 1-1/4 inch input shaft.
    • The 6.0L engines accept a 1-3/8 inch input shaft with 0.98 inch pilot bearing inner diameter.
    Fig 2: Locating Clutch Alignment Tool In Pilot Bearing To Align Clutch Disc
    GF0007148Courtesy of FORD MOTOR CO.
    4. NOTE: Align the index marks if installing the original clutch pressure plate and flywheel.
  4. Install the clutch pressure plate.
    1. Position the clutch pressure plate on the dowels.
      • The diesel engine flywheel has 2 dowels. The gasoline engine flywheel has 3 dowels.
    2. Using a suitable clutch alignment tool, align the clutch disc and the pressure plate.
    3. Install the clutch pressure plate bolts and tighten in a star pattern sequence.
      • For the 5.4L and 6.8L engines, tighten to 45 Nm (33 lb-ft).
      • For the 6.0L engine, tighten to 28 Nm (21 lb-ft).
      Fig 3: Identifying Clutch Alignment Tool
      GF0007149Courtesy of FORD MOTOR CO.
  5. Remove the clutch alignment tool.
  6. Install the transmission. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
  7. Test the system for normal operation.
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