Ford C6AZ-7B066-A Plate - Clutch Pressure

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To remove the dust, use brake system cleaner to flush it into a drain pan, and after wiping the clutch components clean with a rag, dispose of the contaminated materials in a covered, marked container. Disconnecting the battery on later models with a Powertrain Control Unit (PCM) may cause the PCM to lose its memory, leading to abnormal driving symptoms for the first 10 miles until it relearns its adaptive strategy. Accessing the clutch components typically requires removing the transmission (and transfer case on 4WD models) while leaving the engine in place; however, if the engine is being overhauled, check the clutch for wear and replace any worn components. On early models with mechanical linkages, remove the clutch rod and equalizer bar from the transmission. For models with an external slave cylinder, remove and tie it up out of the way without disconnecting the hydraulic line; for those with a concentric slave cylinder, detach the clutch line at the inlet port. For 4WD models, remove the transfer case, followed by the transmission. On 3 and 4-speed models with a separate clutch housing, disconnect the negative battery cable, remove the starter motor bolts, and the bolts retaining the clutch housing to the engine block, noting the presence of shims. To support the clutch disc during removal, install a clutch alignment tool through the hub, and inspect the flywheel and pressure plate for indexing marks, making your own if necessary. Loosen the pressure plate-to-flywheel bolts in a criss-cross pattern until all spring pressure is relieved, then remove the bolts, pressure plate, and clutch disc. Inspect the clutch driven plate assembly, flywheel for defects, pilot bearing, clutch disc lining, release bearing, and pressure plate for wear or damage, replacing components as necessary. If the pilot bearing was removed, install a new one, and before installation, clean the flywheel and pressure plate surfaces thoroughly. Position the clutch disc and pressure plate against the flywheel using the alignment tool, ensuring proper installation, and tighten the pressure plate-to-flywheel bolts lightly in a criss-cross pattern. Center the clutch disc and tighten the bolts gradually, then remove the alignment tool. If applicable, install the clutch release bearing and lever or concentric slave cylinder, followed by the clutch housing, ensuring shims are reinstalled if present. Finally, install the transmission and transfer case, reconnect the slave cylinder or clutch line as needed, and bleed the clutch hydraulics if required, then reinstall the clutch rod and equalizer bar on early model mechanical linkages and adjust the linkage.

The transmission must be removed and engine supported properly to take out and evaluate clutch components. Toward the flywheel, on the pressure plate, locating marks should be looked for. Including clutch disc and pressure plate, undo the pressure plate-to-flywheel bolts. Inspect all clutch parts including pilot bearing and flywheel. If needed, replace the release bearing as well as the clutch disc. Additionally, inspect the surfaces of the pressure plate and fingers of the diaphragm spring. Finally, the clutch disc should be aligned with the flywheel and its bolts tightened to assemble it back together then reinstall the transmission then lower vehicle.

It should be pointed out that the clutch driven disc contains asbestos that is known to cause cancer, therefore it is most unadvisable to clean clutch surfaces with compressed air and should not inhale any dust off such surfaces; as an option; a commercially available brake cleaning fluid may be used. To replace clutch parts on 1983-84 2.0L and 2.3L models first turn off the ignition, and remove the clutch master cylinder from the clutch pedal, then jack up the car and safely support it. Take off the dust shield from the clutch housing, disconnect the hydraulic clutch linkage and taken out the starter as well as the transmission. Locate the assembled position of the pressure plate and the cover on the flywheel and then slacken the bolts of the pressure plate in equal ratio so as to expand the clutch springs and then remove the pressure plate along with its cover and the clutch disc but you may have to replace the pilot bearing also in case it is required. For installation, set the clutch disc on the flywheel with the help of alignment tool, insert the pressure plate and cover and tighten the retaining bolts to 15-24 ft. lbs. Before that, a tentative alignment must be present but before the alignment tool is removed. Replace the transmission, bolt the hydraulic clutch linkage, dust shield, and starter in place, lower the car, connect the clutch hydraulic system master cylinder to the clutch pedal, check for proper function of the clutch hydraulic distribution system, at last reconnect the ground terminal of the battery. The process resembles that of with the 1982-84 models starting from disconnecting the negative battery cable and the clutch hydraulic system master cylinder, lifting the car, removing the starter and disconnecting the hydraulic coupling at the transmission for the 1985-90 models. To dismantle the assembly, first it is essential to clean the surrounding of the hose and slave cylinder to avoid the entrance of fluids; then locate the position of the pressure plate and cover and free and loosen the bolts connecting the pressure plate cover assembly and clutch disc and take out the pressure plate, cover assembly clutch disc and replace the pilot bearing if required. When installing, place the clutch disc on the flywheel by using the correct alignment tool, the pressure plate and cover assembly must be aligned on the previous marks, and finally, screw the bolts in with the force of 15-25 ft. lbs. in the correct fashion and then withdraw the pilot tool. Last, fit the transmission, join the coupling to the slave cylinder and finally fix the hydraulic clutch master cylinder push rod to the clutch pedal.

To remove the dust, use brake system cleaner to flush it into a drain pan, and after wiping the clutch components clean with a rag, dispose of the contaminated materials in a covered, marked container. Disconnecting the battery on later models with a Powertrain Control Unit (PCM) may cause the PCM to lose its memory, leading to abnormal driving symptoms for the first 10 miles until it relearns its adaptive strategy. Accessing the clutch components typically requires removing the transmission (and transfer case on 4WD models) while leaving the engine in place; however, if the engine is being overhauled, check the clutch for wear and replace any worn components. On early models with mechanical linkages, remove the clutch rod and equalizer bar from the transmission. For models with an external slave cylinder, remove and tie it up out of the way without disconnecting the hydraulic line; for those with a concentric slave cylinder, detach the clutch line at the inlet port. For 4WD models, remove the transfer case, followed by the transmission. On 3 and 4-speed models with a separate clutch housing, disconnect the negative battery cable, remove the starter motor bolts, and the bolts retaining the clutch housing to the engine block, noting the presence of shims. To support the clutch disc during removal, install a clutch alignment tool through the hub, and inspect the flywheel and pressure plate for indexing marks, making your own if necessary. Loosen the pressure plate-to-flywheel bolts in a criss-cross pattern until all spring pressure is relieved, then remove the bolts, pressure plate, and clutch disc. Inspect the clutch driven plate assembly, flywheel for defects, pilot bearing, clutch disc lining, release bearing, and pressure plate for wear or damage, replacing components as necessary. If the pilot bearing was removed, install a new one, and before installation, clean the flywheel and pressure plate surfaces thoroughly. Position the clutch disc and pressure plate against the flywheel using the alignment tool, ensuring proper installation, and tighten the pressure plate-to-flywheel bolts lightly in a criss-cross pattern. Center the clutch disc and tighten the bolts gradually, then remove the alignment tool. If applicable, install the clutch release bearing and lever or concentric slave cylinder, followed by the clutch housing, ensuring shims are reinstalled if present. Finally, install the transmission and transfer case, reconnect the slave cylinder or clutch line as needed, and bleed the clutch hydraulics if required, then reinstall the clutch rod and equalizer bar on early model mechanical linkages and adjust the linkage.

In particular, it is necessary to use gloves when performing work on clutch components, for example, protection against sharp ring gear teeth and keep away from the dust, wearing first rubber or latex gloves and then cloth or leather gloves. Some clutch elements are mounted where the transmission is fitted, and thus, could only be reached after the transmission has been detached Clutch components are relatively cheap, and thus, it is recommended that they be inspected for wear and replaced whenever the engine is being removed. Start with the removal of the transmission, follow by loosening the negative battery terminal cables and raising the vehicle by safe jack points. In order to gain additional support for the clutch disc place an alignment tool through the clutch disc hub and note the alignment of the flywheel and pressure plate for reassembly. Loose the pressure plate to the Flywheel bolts by turning them in a crossed fashion until they can be turned out with bare hands and then remove the pressure plate and clutch disk. To all parts of the assembly, look for signs of wear, possible oil contamination, cracks, and the like, and be sure that the thickness of the clutch disc lining is at least 1/16 inch higher than the rivet heads. Likewise, the release bearing should likewise be changed with the clutch disc; the pressure plate, as well, should be checked for damages. In the case where the original pressure plate is being 'recycled' the final adjustment has to be made on a hydraulic press. All machined surfaces should be cleaned for installation; the clutch disc and pressure plate have to be lined up with the flywheel. After that, fasten the pressure plate-to-flywheel bolts equally in a diagonal sequence in order to minimize distortion, lubricate the bearings of the release, and set back the whole transmission and all other parts which were previously removed and then finally lower the car.

Carefully inspect the flywheel and pressure plate for indexing marks. If they cannot be found, scribe marks yourself so the pressure plate and the flywheel will be in the same alignment during installation.

Reinstall the transmission and all previously removed components. Lower the vehicle, reactivate the air suspension system if applicable, and you're done with the installation.

The clutch disc and pressure plate are positioned against the flywheel, aligned with an alignment tool, and tightened in a criss-cross pattern.