Ford Falcon. Manual — part 255

308-01-7 Clutch 308-01-7

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

Binding of the disc on the input shaft

Check splines for burrs, rusting and

damage. Clean up splines and

splines

lubricate with the specified lubricant

Air in hydraulic system

Bleed hydraulic system

Low fluid level in hydraulic clutch

Bleed clutch system and fill clutch fluid

system

reservoir

Replace CSC. Refer to Section

CSC damaged

308-02.

Clutch master cylinder damaged

Replace master cylinder

NOTE: CSC - Concentric Slave Sylinder
SAC - Self Adjusting Clutch (not XR6 Turbo)

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308-01-8 Clutch 308-01-8

GENERAL PROCEDURES

2. Adjust the clutch pressure plate.

Pressure Plate Inspection

1. Rotate the adjusting ring counter clokwise

1. Inspect the friction surface of the pressure plate

until the tension springs are compressed. In

for burn marks, scoring or ridges, and warpage.

compressed form the springs should not be

Generally, pressure plate resurfacing is not

greater than 14 mm.

recommended. However, minor burn marks,

2. Hold adjusting ring while releasing the

scores or ridges may be removed.

pressure on the clutch diaphragm fingers.

2. During the resurfacing process, the flatness of the

pressure plate must be maintained. If the

pressure plate is badly heat checked, or deeply

scored, replace it.

3. Clean the pressure plate and flywheel to be sure

the surfaces are free from any oil film. Do not use

cleaners with petroleum base, and do not

immerse the pressure plate in solvent.

4. Prior to fitment, insure the self adjusting clutch

pressure plate is reset as outlined in this section.

Clutch Disc Inspection

1. Inspect the clutch disc facings for oil or grease.

Eliminate the source of any oil or grease before

replacing the disc. Excessive grease will

contaminate the disc facings. Too much lubricant

in the transmission vent will force the transmission

lubricant past the input shaft seal and into the disc

facings.

2. Inspect the clutch disc for worn or loose facings.

Check the disc for distortion and for loose rivets at

the hub. Check for broken springs and springs

that can be moved radially. Springs that can be

moved laterally are acceptable.

3. Replace the disc assembly if any of these defects

are present. Be especially careful when installing

a new disc to avoid dropping it or contaminating it

with oil or grease. Check that the disc will slide on

the input shaft prior to installation.

Clutch Pressure Plate Adjustment

(XR6 Turbo Variant)

NOTE: The clutch pressure plate should always be

adjusted before installation.

1. Compress the clutch diaphragm fingers.

1. Position the clutch pressure plate in a press.

2. Use a suitable adapter and press the clutch

diaphragm fingers until the adjusting ring

moves freely.

WARNING: Do not over-travel as damage will

occur and clamp load will be reduced.

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308-01-9 Clutch 308-01-9

REMOVAL AND INSTALLATION

Vehicle Item

Specification

QTY

Disc and Pressure Plate

variant

XR6T Screw -

Grade 8.8 S36D

6

The following illustrations show the removal and

M8x1.25x16

Surface finish

installation procedure for the standard I6 pressure

HEX FLG HD

plate and clutch disc, alone. However the

accompanying removal and installation instructions

All V8 Bolt -

N808969-S100

6

are pertinent to standard I6, XR6T and V8 clutch

M10x1.5x28.5

systems, which are alike. As such the following

HEX FLG HD

instructions should be followed when assembling

PILOT

and/or disassembling any of these clutch systems.

Removal

NOTE: All V8 and I6 clutch systems, except XR6T

1. Remove the transmission. For additional

clutch, utilise a self-adjusting pressure plate. In such

information, refer to Section 308-03.

systems the friction surface of the pressure plate

ratchets progressively forward as the clutch disc

2. Remove the bolts, clutch pressure plate and the

becomes worn. As such the ratcheting mechanism in

clutch disc.

the self-adjusting pressure plates must be reset

CAUTION: If the clutch disc and pressure

before reassembling the clutch system with a new

plate are to be reinstalled, bolts must be

clutch disc in place. The procedure for resetting these

removed evenly or permanent damage to the

pressure plates are in clutch pressure plate

diaphragm spring will occur resulting in

adjustment covered earlier in this section.

complete clutch release.

Special Tool(s)

If the parts are to be reused, index-mark the

clutch pressure plate to the flywheel. Also

Aligner, Clutch Disc

inspect the pressure plate and clutch disc as

All I6: Tool 308-257 (E9276) or

outlined in this section.

Transmission Input Shaft (23T)

All V8: Generic Tool or Input

Shaft (10T)

Installation
1. Lubricate the transmission input shaft pilot

bearing with grease.

Materials

Item

Specification

High-Temperature 4x4

ESA-M1C198-A

Front Axle and Wheel

Bearing Grease
Threadlock and Sealer

Locktite 243

Hardware - Pressure Plate-to Flywheel

Vehicle Item

Specification

QTY

variant

All I6

Bolt -

E602550-S36D

6

(except M8x1.25x25.5

XR6T) HEX HD

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308-01-10 Clutch 308-01-10

REMOVAL AND INSTALLATION (Continued)

2. Using the special tool, position the clutch disc on

5. Install

the

transmission.

the flywheel.

1. For additional information, refer to Section

308-03.

Flywheel — I6 (all variants including

XR6 Turbo)

Materials

Item

Specification

Threadlock and Sealer

Loctite 243 or equivelant

E0AZ-19554-AA

Loctite

Hardware - Flywheel-to-crankshaft

Vehicle Item

Specification

QTY

variant

All I6

Bolt -

V800322

6

3. Using the special tool, align the clutch disc and fit

(except M10x1.25x25

the clutch pressure plate. Install the bolts and

XR6T) HEX HD

tighten in a star pattern sequence.

XR6T Screw -

V800524

6

NOTE: If reusing the clutch pressure plate and

M8x1.25x19

flywheel, align the marks made during removal.

HEX FLG HD

4. Remove

tool.

All V8 Bolt -

N808139-S100

8

M10x1x26.5

HEX HD

Removal
1. Remove the transmission. For additional

information, refer to Section 308-03.

2. Remove the clutch disc and pressure plate. For

additional information, refer to Disc and Pressure

Plate in this section.

3. Remove four of the six bolts. Leaving two

opposing bolts in place, loosely.

CAUTION: Two bolts should be loosened

but left in to prevent the flywheel from falling.

4. Separate the flywheel from the crankshaft.
5. Remove the bolts remaining in the crankshaft.
6. Remove the flywheel.

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