Ford Falcon. Manual — part 254
308-01-3 Clutch 308-01-3
DESCRIPTION AND OPERATION
Clutch
Introduction
Three clutch variants are used across the manual BA
Falcon range. All manual I-6 vehicles, except XR6T
are fitted with a one-piece flywheel and 254mm
clutch. Manual XR6T vehicles are fitted with a
two-piece flywheel and a heavy-duty 267mm clutch.
All manual V8 vehicles are fitted with a one-piece
flywheel, 292mm pressure plate and 280mm clutch
disc to provide a high torque capacity.
Clutch Function
The primary function of the clutch system is to
connect and disconnect engine power to the
transmission upon driver command.
Clutch System Components — STD I6
Item
Description
Item
Description
4
Clutch pressure plate
1
Flywheel
5
Clutch slave cylinder/clutch release hub
2
Transmission input shaft pilot bearing
and bearing
3
Clutch disc
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308-01-4 Clutch 308-01-4
DESCRIPTION AND OPERATION (Continued)
Clutch System Components —XR6 Turbo
Item
Description
1
Flywheel (2 piece assembly)
2
Transmission input shaft pilot bearing
3
Clutch disc
4
Clutch pressure plate
5
Clutch slave cylinder/clutch release hub
and bearing
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308-01-5 Clutch 308-01-5
DESCRIPTION AND OPERATION (Continued)
Clutch System Components — V8 Standard
(3 valve) & XR8 (4 Valve)
A pilot bearing supports the end of the input shaft.
Item
Description
The bearing does not require lubrication unless the
1
Flywheel
clutch system is serviced.
2
Transmission input shaft pilot bearing
The clutch does not require pressure plate re-setting
3
Clutch disc
after disasembly or disc renewal.
4
Clutch pressure plate
NOTE: The clutch pressure plate should always be
adjusted before installation.
5
Clutch slave cylinder/clutch release hub
and bearing
For Standard I6, XR6 & all V8:
The clutch is a single plate, dry friction clutch disc with
a self-adjusting, diaphragm-style spring clutch
pressure plate.
The clutch operating mechanism consists of a clutch
slave cylinder with an integral release bearing.
A pilot bearing supports the end of the input shaft.
The bearing does not require lubrication unless the
clutch system is serviced.
The clutch does not require pressure plate re-setting
after disasembly or disc renewal.
For XR6 Turbo:
The clutch is a single plate, dry friction clutch disc with
diaphragm-style spring clutch plate.
The clutch operating mechanism consists of a clutch
slave cylinder with an integral release bearing.
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308-01-6 Clutch 308-01-6
DIAGNOSIS AND TESTING
Clutch
Symptom Chart
Condition
Source
Action
Clutch does not disengage correctly
Worn clutch disc.
Replace worn or defective parts
Failed pressure plate.
Replace pressure plate
Self Adjusting Clutch (SAC) over
Remove SAC and reset
adjusted.
Air in hydraulic system
Bleed hydraulic system
Damaged Concentric Slave Cylinder
Repair or replace CSC. Refer to
(CSC).
Section 308-02.
Clutch pedal hang-up or excessive
Repair or replace CSC. Refer to
CSC damaged.
clutch pedal effort
Section 308-02.
Master cylinder damaged.
Replace clutch master cylinder
Noisy clutch operation when engine
Replace CSC. Refer to Section
CSC bearing failure
running
308-02.
Clutch disc damaged
Replace clutch disc
Lubricate with engine oil or replace
Noisy clutch operation with engine off
Binding at pedal support bracket
support bracket bushing
Replace CSC. Refer to Section
CSC damaged
308-02.
Binding within pressure plate
Lubricate pressure plate pins
Worn or contaminated clutch lining
Replace defective part. (If grease or oil
Clutch slips or chatters
Grease or oil on clutch facings from:
is causing the clutch to slip, replace
Release bearing
the disc, remove the grease or oil from
Engine
the pressure plate and flywheel and
CSC
reuse if it is not burned or scored.)
Pilot bearing
Repair source of leakage.
Transmission
Weak or failed pressure plate
Replace pressure plate
Loose pressure plate to flywheel bolts
Torque bolts to spec
Loose engine mount bolts
Torque bolts to spec
Replace CSC. Refer to Section
Damaged CSC
308-02.
Failed master cylinder
Replace clutch master cylinder
Intermittent squawk
Flywheel housing misalignment
Replace flywheel housing
Clutch noisy when disengaged (Engine
Pilot bearing worn
Replace pilot bearing
running)
Replace CSC. Refer to Section
CSC bearing worn
308-02.
Clutch spin or drag
Failed pressure plate
Replace pressure plate
Replace clutch disc and degrease
Grease on linings of clutch disc
pressure plate and flywheel
Flywheel housing out of alignment
Align to specifications
SAC over adjusted
Remove SAC and reset
Fit clutch disc correctly, if damaged
Damaged clutch disc
replace
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