How to Replace Clutch Disc and pressure plate?

Ford Explorer Clutch disc and pressure plate removal.


Driven Disc & Pressure Plate
REMOVAL & INSTALLATION

This details will work for
Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005.

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Clutch hydraulic system master cylinder from the clutch pedal

   Starter

   Hydraulic coupling at the transmission

   Transmission from the vehicle
3. Mark the assembled position of the pressure plate in relation to the flywheel to aid during reassemble.
   
   
   Loosen the pressure plate and cover attaching bolts evenly until the pressure plate springs are expanded

   Pressure plate and cover assembly and the clutch disc from the flywheel

   Pilot bearing, only if replacing

To install:

1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft tool T74P-7137-K can enter the clutch pilot bearing and align the disc.
2. When reinstalling the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations.
3. Install or connect the following:
   
   
   Pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Torque the bolts to 15-25 ft. lbs. (21-35 Nm) in the proper sequence. Remove the clutch disc pilot tool

   Transmission into the vehicle

   Starter

   Coupling by pushing the male coupling into the slave cylinder

   Hydraulic clutch master cylinder pushrod to the clutch pedal

   Negative battery cable
4. Bleed the hydraulic clutch system.
   
   
   

   

   Fig. Clutch disc, pressure plate and bearing assembly
   
   
   
   

   

   Fig. Tighten the bolts gradually in the correct sequence to avoid warping the pressure plate

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
   
   NOTE

   If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
   
   
   
   
   Negative battery cable

   Transmission
   
   
   
   
   Bolts, clutch pressure plate and the clutch disc

To install:

1. Lubricate the transmission input shaft pilot bearing with grease.
2. Adjust the clutch pressure plate:
   1. Using a suitable press, 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 stay in the reset position.
3. Position the clutch disc on the flywheel.
4. Align the clutch disc and the clutch pressure plate. Install the bolts and tighten in a star pattern sequence. Torque to 21 ft. lbs. (28 Nm).
   
   NOTE

   An "L" is stamped by three bolt holes on the clutch pressure plate. Tighten these to specification first to ensure correct clutch alignment.
5. Install the transmission.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   NOTE

   If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
   
   
   
   
   Negative battery cable

   Transmission
   
   
   
   
   Bolts, clutch pressure plate and the clutch disc

To install:

1. Lubricate the transmission input shaft pilot bearing with grease.
2. Adjust the clutch pressure plate:
   1. Using a suitable press, 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 stay in the reset position.
3. Position the clutch disc on the flywheel.
4. Align the clutch disc and the clutch pressure plate. Install the bolts and tighten in a star pattern sequence. Torque to 21 ft. lbs. (28Nm).
   
   NOTE

   An "L" is stamped by three bolt holes on the clutch pressure plate. Tighten these to specification first to ensure correct clutch alignment.
5. Install the transmission.

This will help.

Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html