Clutch Assembly: Installation
- Replace release bearing and/or pilot bearing as necessary. Clean sealant from flywheel attaching bolt threads. Replace bolts if sealant cannot be removed. Coat bolt threads with Stud/Bearing Mount Sealer (EOAZ-19554-B), and install flywheel. Tighten bolts in a diagonal sequence to specification. See TORQUE SPECIFICATIONS
table.
- Position clutch disc on flywheel with damper springs facing away from flywheel. On Capri, hold clutch disc in place with Clutch Aligner (T87C-7137-A). Position pressure plate over clutch disc. See Fig 1
.
- If reusing original pressure plate, align marks made during removal. Install pressure plate retaining bolts. Alternately tighten bolts to specification. See TORQUE SPECIFICATIONS6
table. Remove clutch aligner. Place transaxle on transmission jack.
- Lightly coat input shaft splines with Clutch Grease (C1AZ-19590-B). Install transaxle, taking care to align input shaft through the clutch disc spline. Align clutch housing onto engine guide bushings.
CAUTION:
Transaxle aluminum alloy construction requires precise tightening of mounting bolts. Torque specifications must be strictly adhered to. See TORQUE SPECIFICATIONS
table.
- Install transaxle lower attaching bolts and tighten to specification. Using transaxle jack, raise transaxle to correct height and tighten engine bracket bar hook. Install front engine mount and bracket and tighten to specification. Install starter and lower mounting bolts, tighten to specification. On Capri non-turbo, install slave cylinder. Slide extension bar onto transaxle bracket.
- Install control rod to transaxle and tighten bolts and nuts to specification. Install crossmember bolts to specification in sequence, and install crossmember. See Figure
. Install support braces. On all models, install exhaust hanger to crossmember. On Capri turbo, install intermediate shaft and support bearing assembly. On all models, remove transaxle jack.
- Install new circlips on each half-shaft with gap at top of clip grove and slide into transaxle differential. After circlip snaps into place, pull outward on hubs to confirm half-shafts are retained by circlip. Install front suspension components, wire harness, underbody and fender splash shields and front tire assemblies.
- Connect neutral and back-up light switch and ground wire. Fill transaxle with Mercon ATF transmission fluid to specification. Install and adjust clutch cable or slave cylinder line bracket. Lower vehicle and remove engine support bar. Install speedometer cable into transaxle.
- Install battery and/or connect battery cable. Install air cleaner. Adjust pedal free play. See CLUTCH PEDAL FREE PLAY
under ADJUSTMENTS. Recheck transaxle fluid level and road test vehicle.
Courtesy of FORD MOTOR CO.