Clutch Disc and Pressure Plate: Removal

Clutch disc and clutch pressure plate 

1. Remove the transaxle. For additional information, refer to REMOVAL .
2. 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: Inspecting Clutch Pressure Plate

   Courtesy of FORD MOTOR CO.
3. Using the Flywheel Holding Tool, lock the flywheel to the engine.
   Fig 2: Identifying Flywheel Holding Tool

   Courtesy of FORD MOTOR CO.
4. Using a suitable clutch disc aligner, remove the bolts, the clutch pressure plate and the clutch disc.
   NOTE: Loosen each bolt, one turn at a time in a star pattern, until spring tension is released.
   Fig 3: Identifying Flywheel Holding Tool

   Courtesy of FORD MOTOR CO.
5. Using a suitable cleaning solution, clean the clutch pressure plate.
   NOTE: Do not immerse the clutch pressure plate in solvent.
6. Inspect the clutch pressure plate surface for burn marks, scores, flatness, ridges or cracks. For additional information, refer to CLUTCH PRESSURE PLATE CHECK .
   • Maximum clearance for flatness check is 0.3 mm (0.011 in).
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
   • Install a new clutch disc if any of these conditions are present.
   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 - 2.5L or MANUAL TRANSAXLE/TRANSMISSION .
   NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface.
8. Check the clutch disc runout. For additional information, refer to CLUTCH DISC CHECK .
9. If necessary, conduct a Flywheel Runout Check. For additional information, refer to FLYWHEEL RUNOUT CHECK .

   Clutch release bearing and clutch release fork 

10. Remove the clutch release bearing.
    Fig 4: Locating Clutch Release Bearing

    Courtesy 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

    Courtesy 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.
    Fig 6: Locating Clutch Release Fork

    Courtesy of FORD MOTOR CO.