Ford F87Z-7L596-JA Kit - Clutch Repair

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The clutch parts can usually only be reached once the transmission and transfer case are out on 4wd models; the engine does not have to be removed. However, if the engine is being pulled for major rebuild, inspect the clutch for wear and replace that which has been worn, since clutch parts are cheap, then should this part be removed anytime the engine or the transmission is pulled, then it should not be spared the D/I unless it is new or nearly new. First loosen the transmission bolts and then support the engine, ideally with an engine lift, or with a jack and some plank of wood on the engine oil pan. Care must be taken because of the position of the oil pump pickup which is near the bottom of the oil pan and any bending of the pick up could lead to lack of oil. Before removing the clutch disc use clutch alignment tool through the clutch disc hub to support the clutch disc. Ensure there are index marks on the flywheel and pressure plate and if not make your own when reassembling the engine. Tighten the pressure plate to flywheel bolts in diagonal sequence to reduce the spring tension then remove the pressure plate and clutch disc. When inspecting the flywheel, ensure that is has no cracks and other vices and if necessary, it should be matted. Check the pilot bearing, clutch disc lining and the release bearing and if they are worn replace them. Inspect the pressure plate for signs of wear and possible damage and if the plate is excessively worn it should be replaced. Concerning installation, it is recommended that you clean the contour of the flywheel and the pressure plate without using any oil or grease. Insert the alignment tool to fit into slots on the clutch disc and pressure plate and align it well on the fitted flywheel. In case the pressure plate comes with an adjustment ring then this should be adjusted before it is fitted on the engine. Tighten the pressure plate-to-flywheel bolts until they are as tight as you can get them with your fingers, align the clutch disc with the transmission input shaft, and then tighten the bolts in a diagonal pattern to the required amount of torque called out in your shop manual. Last but not the least, the clutch release bearing, transmission assembly, and all other parts removed should be refitted making sure that all the bolts and screws are tightened to their optimal torque.

The release bearing should also be replaced along with the clutch disc.