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1. Check pressure plate surfaces for scoring, cracks or discoloration. Remove minor scratches or discoloration with fine emery cloth. Check pressure plate diaphragm spring fingers for discoloration, scoring, broken or bent segments. Ensure all spring ends are the same height. 2. Check clutch disc lining surface for hardening or presence of oil. Check for worn clutch disc lining. Check for loose lining rivets. Measure depth of rivet heads. Minimum allowable rivet depth is .012" (0.3 mm). Check for wear or rust on splines. Rust may be 3. Check flywheel surface for marks, scoring or discoloration. Minor surface repairs may be removed with fine emery cloth. Flywheel must be machined if scoring, runout, or discoloration is excessive. Maximum flywheel runout is .008" (0.2 mm). Check for damaged or worn 4. Check pilot bearing for wear. Check clutch release/throw out bearing for damage or wear at contact points. Rotate bearing in both directions and check for binding or abnormal noise. Installation 1. 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 TORQUE SPECIFICATIONS at the end of this article. 2. Position clutch disc on flywheel with damper springs facing away from flywheel. Hold clutch disc in place with Clutch Aligner (T77F- 7137-A ). Position pressure plate over clutch disc. See Fig. 4 . 3. If reusing original pressure plate, align marks made during removal. Install pressure plate retaining bolts. Alternately tighten bolts to specification. See TORQUE SPECIFICATIONS at the end of this article. Remove clutch aligner. Place transaxle on transmission jack. 4. 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. 5. 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, 6. Install control rod to transaxle and tighten bolts and nuts to specification. On Festiva, install crossmember and support braces. Install support braces. On all models, install exhaust hanger to crossmember. Remove transaxle jack. 7. 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 8. 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 9. 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.
Fig. 4: Exploded View Of Clutch Assembly
Courtesy of FORD MOTOR CO. CLUTCH RELEASE BEARING & FORK Removal Remove transaxle. Remove release lever bolt and slide release bearing off. See Fig. 4 . Remove release lever shaft and remove release lever. CAUTION: Transaxle aluminum alloy construction requires precise tightening of mounting bolts. Torque TORQUE SPECIFICATIONS . NOTE: The clutch release bearing is pre-lubricated and permanently sealed. DO NOT clean release bearing in |