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Clutch Disc and Pressure Plate: Removal

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the transaxle. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION .
  2. Inspect the clutch pressure plate.
    • Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments.
    • Using the special tool, rotate the flywheel and check for spring ends that are higher or lower than the rest.
    • The specification is 0.6 mm (0.02 in) maximum.
      Fig 1: Inspecting Clutch Pressure Plate
      G04682076Courtesy of FORD MOTOR CO.
  3. Using the special tool, lock the flywheel to the engine.
    Fig 2: Identifying Special Tool - 303-103
    G04682077Courtesy of FORD MOTOR CO.
    4. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
    CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
    Fig 3: Locating Bolts And Clutch Disc Aligner
    G04682078Courtesy of FORD MOTOR CO.
  4. Using a suitable clutch disc aligner, remove the bolts, the clutch pressure plate and the clutch disc.
    5. CAUTION: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent.
  5. Using a suitable commercial alcohol-based solvent, clean the clutch pressure plate.
  6. Inspect the clutch pressure plate surface for burn marks, scores, flatness, ridges or cracks. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
    • Maximum clearance for flatness check is 0.3 mm (0.012 in).
    7. CAUTION: 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 - 2.3L or MANUAL TRANSAXLE/TRANSMISSION .
    NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface.
    NOTE: Install a new clutch disc if any of the following conditions are present.
  7. 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.
  8. Check the clutch disc runout. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
  9. If necessary, carry out a flywheel runout check. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
  10. Remove the clutch release bearing.
    Fig 4: Locating Clutch Release Bearing
    G04682079Courtesy of FORD MOTOR CO.
  11. 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: Inspecting Clutch Release Bearing For Wear Or Damage
      G04682080Courtesy of FORD MOTOR CO.
  12. Inspect the release bearing guide tube for wear or damage.
    • Slide the release bearing on the guide tube. Check for roughness or sticking.
  13. Remove the clutch release fork. Inspect the fork for wear or damage.
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