Clutch Disc and Pressure Plate: Removal

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

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.

Clutch disc and clutch pressure plate

Remove the transaxle. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION -- FUSION & MILAN article.
Inspect the clutch pressure plate.
- Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments.
- Using the Dial Indicator Gauge with Holding Fixture, rotate the flywheel and check for spring ends that are higher or lower than the rest.
  - The specification is 0.6 mm (0.023 in) maximum.
    
    Fig 1: Checking Spring Ends Using Dial Indicator Gauge With Holding Fixture
    Courtesy of FORD MOTOR CO.
Using the Flywheel Holding Tool, lock the flywheel to the engine.

Fig 2: Locking Flywheel To Engine Using Flywheel Holding Tool
Courtesy of FORD MOTOR CO.

NOTE: Loosen each bolt, one turn at a time in a star pattern, until spring tension is released.

Fig 3: Removing Clutch Pressure Plate And Clutch Disc Bolt Using Suitable Clutch Disc Aligner

Courtesy of FORD MOTOR CO.

Using a suitable clutch disc aligner, remove the bolts, the clutch pressure plate and the clutch disc.

NOTE: Do not immerse the clutch pressure plate in solvent.

Using a suitable cleaning solution, clean the clutch pressure plate.
Inspect the clutch pressure plate surface for burn marks, scores, flatness, ridges or cracks. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION & CLUTCH - GENERAL INFORMATION - FUSION & MKZ article.
- Maximum clearance for flatness check is 0.3 mm (0.011 in).

NOTE: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal or transmission input shaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation. For additional information, refer to ENGINE MECHANICAL - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article or MANUAL TRANSAXLE/TRANSMISSION -- FUSION & MILAN article.

NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface.

Inspect the clutch disc for the following:
- Oil or grease saturation
- Worn or loose facings
- Warpage or loose rivets at the hub
- Wear or rust on the splines
- Install a new clutch disc if any of these conditions are present.
Check the clutch disc runout. For additional information, refer to Clutch Disc Check in MANUAL TRANSAXLE/TRANSMISSION & CLUTCH - GENERAL INFORMATION - FUSION & MKZ article.
If necessary, conduct a Flywheel Runout Check. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION & CLUTCH - GENERAL INFORMATION - FUSION & MKZ article.
Clutch release bearing and clutch release fork
Remove the clutch release bearing.

Fig 4: Locating Clutch Release Bearing
Courtesy of FORD MOTOR CO.
Inspect the clutch release bearing for wear or damage.
- Rotate the bearing while applying pressure in the axial direction. If the bearing feels rough, sticks or has excessive resistance, install a new bearing.
  
  Fig 5: Rotating Bearing
  Courtesy of FORD MOTOR CO.
Inspect the release bearing guide tube for wear or damage.
- Slide the release bearing on the guide tube. Check for roughness or sticking.
Remove the clutch release fork. Inspect the fork for wear or damage.

Fig 6: Locating Clutch Release Fork
Courtesy of FORD MOTOR CO.