Clutch Disc: Service and Repair
Clutch Disc and Pressure PlateRemoval
1. Remove the transmission.
2. Index-mark the clutch pressure plate and the flywheel, if reinstalling these parts.
3. Remove the bolts, the clutch pressure plate, and the clutch disc.
4. Inspect the transmission input shaft pilot bearing:
^ for misalignment and looseness in the crankshaft (gasoline engine) or flywheel (diesel engine).
^ needle rollers for scoring, discoloration, wear, and broken rollers.
^ seal for damage and lubricant leakage.
- Install a new transmission input shaft pilot bearing if any of these conditions are present.
Installation
1. CAUTION: Sometimes, when removing the transmission, the input shaft will remove a considerable amount of lubricant from the transmission input shaft pilot bearing.
Lubricate the transmission input shaft pilot bearing, as necessary.
^ Use Krytox High-Temperature Grease.
2. CAUTION: When installing the original clutch pressure plate on 5.4L, 6.0L and 6.8L applications, reset the wear indicator before installing the clutch pressure plate on the flywheel.
Reset the wear indicator.
1 Using a suitable press and adapter, press downward on the fingers until the adjusting ring moves freely.
2 Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3 Release the pressure on the fingers. The adjusting ring will now stay in the reset position.
3. Position the clutch disc on the flywheel and the clutch alignment tool in the pilot bearing to align the clutch disc.
^ The 5.4L/6.8L engines accept a 1 1/4 inch input shaft.
^ The 6.0L engines accept a 1 3/8 inch input shaft with 0.98 inch pilot bearing inner diameter.
^ The 7.3L engines accept a 1 3/8 inch input shaft with 0.67 inch pilot bearing inner diameter.
4. NOTE: Align the index marks if installing the original clutch pressure plate and flywheel.
Install the clutch pressure plate.
1 Position the clutch pressure plate on the dowels.
^ The diesel engine flywheel has two dowels. The gasoline engine flywheel has three dowels.
2 Using a clutch alignment tool, align the clutch disc and the pressure plate.
3 Install the bolts and tighten in a star pattern sequence.
4 Remove the special tool.
5. Install the transmission.
6. Test the system for normal operation.