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Clutch Disc and Pressure Plate: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 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.
  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.
      Fig 1: Reseting Wear Indicator
      G03923336Courtesy of FORD MOTOR CO.
  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: Positioning Clutch Alignment Tool In Pilot Bearing For Aligning Clutch Disc
      G03923337Courtesy 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 two dowels. The gasoline engine flywheel has three 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.
    4. Remove the clutch alignment tool.
      Fig 3: Installing Clutch Pressure Plate
      G03923338Courtesy of FORD MOTOR CO.
  5. Install the transmission. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED .
  6. Test the system for normal operation.
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