Clutch Disc and Pressure Plate: Removal

WARNING: This page is about a different car, the 2009 Mercury Milan and 2009 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Remove the transaxle. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION article.
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

Courtesy of FORD MOTOR CO.

Using the special tool, lock the flywheel to the engine.

Fig 2: Identifying Special Tool (303-103)

Courtesy of FORD MOTOR CO.

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

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

Fig 3: Locating Bolts And Clutch Disc Aligner

Courtesy of FORD MOTOR CO.

NOTE: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent.

Using a suitable commercial alcohol-based solvent, 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 AND CLUTCH - GENERAL INFORMATION article.
- Maximum clearance for flatness check is 0.3 mm (0.012 in).

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 article or MANUAL TRANSAXLE/TRANSMISSION 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 the these conditions are present.
Check the clutch disc runout. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
If necessary, conduct a flywheel runout check. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
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: Inspecting Clutch Release Bearing For Wear Or Damage

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.