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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 669 (Clutch System - F250-F550 Super Duty) >> Removal And Installation >> Clutch Disc and Pressure Plate >> Installation

Clutch Disc and Pressure Plate: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 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 on 5.4L, 6.0L and 6.8L applications, reset the wear indicator before installing the clutch pressure plate on the flywheel.
    Fig 1: Rotating Adjusting Ring Counterclockwise
    G02776366Courtesy 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: Aligning Tool In Pilot Bearing To Align Clutch Disc
    G02776367Courtesy of FORD MOTOR CO.
    4. NOTE: Align the index marks if installing the original clutch pressure plate and flywheel.
    Fig 3: Removing Special Tool
    G02776368Courtesy of FORD MOTOR CO.
  4. Install the clutch pressure plate.
    1. Position the clutch pressure plate on the dowels.
      1. The diesel engine flywheel has two dowels. The gasoline engine flywheel has three dowels.
    2. Using a clutch alignment tool, align the clutch disc and the pressure plate.
    3. Install the bolts and tighten in a star pattern sequence.
    4. Remove the special tool.
  5. Install the transmission. Refer to MANUAL TRANSAXLE/TRANSMISSION - ZF 6 SPEED .
  6. Test the system for normal operation.
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