Clutch Disc and Pressure Plate: Removal

WARNING: This page is about a different variant/trim than selected.

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.