clutch FORD MUSTANG 1969 Volume One Chassis

05-02-04
General Clutch Service

05-02-04

CLEANING AND INSPECTION

RELEASE BEARING

Wipe all oil and dirt off the release

bearing. The bearing is prelubricated

and should not be cleaned with sol-

vent.

Inspect the bearing retainer for

loose spring clips and rivets.

Inspect the release bearing assembly

for burrs which may cause the assem-

bly to drag on the transmission bear-

ing retainer. Any such burrs should be

cleaned up with fine crocus cloth. If

burrs are found, inspect the transmis-

sion input shaft bearing retainer for

evidence of scoring. Any scoring

should be polished out with crocus

cloth. Coat the bearing retainer with a

thin film of lithium-base grease

(C3VY-19586-A). Prior to release

bearing installation, apply a light film

of lithium base grease (C3VY-

19586-A) on both sides of the release

lever fork where it contacts the release

bearing hub and retaining springs.

Apply a light film of lithium base

grease (C3VY-19586-A) plate to the

release bearing surface that contacts

the pressure plate fingers. Carefully

fill the grease groove inside the bear-

ing hub with lithium base grease (no

polyethylene). Clean all excess grease

from the bore of the bearing hub. Ex-

cess grease will be forced onto the

spline by the transmission input shaft

bearing retainer and will contaminate

the clutch disc. Also, care must be

exercised when applying lubricants to

the release bearing, release bearing

hub and the release lever fork to avoid

excessive grease from contaminating

the clutch disc.

Hold the bearing inner race and ro-

tate the outer race while applying

pressure to it. If the bearing rotation

is rough or noisy, replace the bearing.

Most release bearing failures are

caused by improper clutch pedal ad-

justments. If the clutch linkage does

not have enough free travel, the re-

lease bearing will constantly touch the

release fingers and will spin whenever

the engine is running.

When installing a release bearing on

vehicles equipped with separate hub

and bearing, use the tool shown in

Fig. 5.

Release bearing failure can be

caused by the release lever contact

points being out of plane. Check the

wear on the release bearing assembly

where the release lever contacts it.

If one side of the assembly shows

more wear than the other, the release
lever is bent out of plane, or is not

centering on the bracket on the fly-

wheel housing.

Misalignment between the engine

and transmission can cause release

bearing failure. Other symptoms of

misalignment are transmission jump-

ing out of gear, especially third gear,

drive line vibration; excessive wear in

the pilot bushing, excessive clutch disc

spin time resulting in gear clash, and

excessive transmission gear wear.

PRESSURE PLATE AND COVER

Inspect the surface of the pressure

plate for burn marks, scores, or rid-

ges.
Generally, pressure plate resur-

facing is not recommended. However

minor burn marks, scores, or ridges

may be removed. During the resurfac-

ing process, the flatness of the pres-

sure plate must be maintained. If the

pressure plate is badly heat-checked or

deeply scored, replace the pressure

plate and cover assembly. Clean pres-

sure plate and flywheel surfaces with a

suitable solvent, such as alcohol to be

sure the surfaces are free from any oil

film. Do not use cleaners with petrole-

um base, and do not immerse the

pressure plate in the solvent.

Place the plate on the floor, being

careful not to score or scratch the sur-

face.
Force each individual finger

down, then release quickly. If the fin-

ger does not return quickly, a binding

condition is indicated, and the pres-

sure plate should be replaced.

The pressure plate should be lubri-

cated with a lithium-base grease be-

tween the driving lugs and the edges

of the pressure plate openings, as

shown in Fig. 6. Depress the pressure

plate fingers fully, apply the lubricant,

and then move the fingers up and

down until the lubricant is worked in.

Do not apply excessive lubricant.

CLUTCH DISC

Inspect the clutch disc facings for

oil or grease. Eliminate the source of

any oil or grease before replacing the

disc. An excessive amount of grease in

the pilot bushing or release bearing

hub will find its way to the disc fac-

ings.
Too much lubricant in the trans-

mission or a plugged transmission

vent will force the transmission lubri-

cant out the input shaft and onto the

disc facings. Also, rear main bearing

oil seal leaks or oil leaks from the fly-

wheel mounting bolts can contaminate

the clutch disc.
Inspect the clutch disc for worn or

loose facings. Check the disc for worn

or loose facings. Check the disc for

distortion and for loose rivets at the

hub.
Check for broken springs.

Springs loose enough to rattle will not

cause noise when the car is operating.

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.

PILOT BUSHING

Check the fit of the clutch pilot

bushing in the bore of the crankshaft.

The bushing is pressed into the

crankshaft and should not be loose.

Inspect the inner surface of the bush-

ing for wear or a bell-mouthed condi-

tion. If the bushing is worn or dam-

aged, replace the bushing with a new

service bearing. Refer to the applica-

ble engine for the replacement proce-

dure.

C 1785-A

FIG. 5—Installing Clutch Release

Bearing on Hub

PRESSURE PLATE

AND COVER

DRIVING

LUG
FLYWHEEL

C2048-A

FIG. 6—Pressure Plate Lubrication

Pointsprocarmanuals.com

05-03-01
Clutch

05-03-01

PART 5-3 Clutch

COMPONENT INDEX

CLUTCH EQUALIZER BAR AND/OR

BUSHING

Removal and Installation

CLUTCH PEDAL ASSIST SPRING

Removal and Installation

CLUTCH PEDAL AND/OR BUSHING

Removal and Installation

CLUTCH PEDAL, PEDAL ASSIST SPRING

AND/OR BUSHING

Removal and Installation

CLUTCH PEDAL FREE PLAY ADJUSTMENT

CLUTCH REMOVAL AND INSTALLATION

DESCRIPTION
MODEL APPLICATION
All
Models
Ford

03-05

N/A

N/A

03-03

03-03

03-05

03-01
Mercury
03-05

N/A

N/A

03-03

03-03

03-05

03-01
Meteor
03-05

N/A

N/A

03-03

03-03

03-05

03-01
Cougar
03-05

N/A

N/A

03-04

03-03

03-05

03-01
Fairlane
03-05

03-03

03-04

N/A

03-03

03-05

03-01
Falcon
03-05

03-03

03-04

N/A

03-03

03-05

03-01
Montego
03-05

03-03

03-04

N/A

03-03

03-05

03-01
Mustang
03-05

N/A

N/A

03-04

03-03

03-05

03-01
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

N/A

N/A

N/A

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.

DESCRIPTION

DESCRIPTION

The clutch is of the centrifugal sin-

gle dry disc type and consists of the
clutch disc, pressure plate and the

clutch release bearing.

CLUTCH PEDAL

7519

351538-S

VIEW A

BUSHING-2 REQ'D.

7517
C2055-A

FIG.
1—Clutch
Pedal and Linkage Adjustments —
Ford,
Mercury, Meteor
procarmanuals.com

05-03-02

Clutch
05-03-02

IN-VEHICLE ADJUSTMENTS AND REPAIRS

SPRING-7A600

EQJALIZER ROD-7A516

EQUALIZER BAR-7528

SPRING-7523
FELTWASHER-375475

EQUALIZER
EQUALIZER ROD-7A516

LOCKNUT-34809-S7

RELEASE ROD/

7B543

SNAP RING-7A629

OUTER BRACKET-7507

PIVOT-7A531

RELEASE ROD-7B543

RELEASE ROD-7B543

OUTER EQUALIZER BAR-7528
BUSHING-7526

SPRING-7A632

SNAP RING-7A629

FELT WASHER-375475-S
BUSHING-7543 SPRING-7523

FELT WASHER-358979-S

SPRING-7545

FAIRLANE AND MONTEGO

390 AND 428 ENGINES
FAIRLANE AND MONTEGO

302 AND 351

FIG.
2—Clutch
Pedal and Linkage Adjustment — Fairlane, Montego and Falcon

ASSIST SPRING BRACKET 7535-
ASSIST SPRING 7B572

SPRING

7A632

RELEASE ROD 7B543

390 ENGINE

SAME AS MAIN VIEW

EXCEPT AS SHOWN
351 ENGINE

SAME AS MAIN VIEW

EXCEPT AS SHOWN

C2056-A

FIG.
3—Clutch
Pedal and Linkage Adjustment — Mustang, Cougarprocarmanuals.com

05-03-03
Clutch
05-03-03

CLUTCH PEDAL

ADJUSTMENTS

Adjust
the
clutch pedal free travel

whenever
the
clutch does
not
disen-

gage properly,
or
when
new
clutch

parts
are
installed. Improper adjust-

ment
of the
clutch pedal
is one of the

most frequent causes
of
clutch failure

and
can be a
contributing factor
in

some transmission failures.

FREE TRAVEL

1.
Disconnect
the
clutch return

spring from
the
release lever.

2.
Loosen
the
release lever
rod

locknut
and
adjusting
nut
(Figs.
1, 2

and
3).

3.
Move
the
clutch release lever

rearward until
the
release bearing

lightly contacts
the
clutch pressure

plate release fingers.

4.
Adjust
the rod
length until
the

rod seats
in the
release lever pocket.

5.
Insert
the
specified feeler gauge

between
the
adjusting
nut and the

swivel sleeve. Then tighten
the
adjust-

ing
nut
against
the
gauge finger tight.

6. Tighten
the
locknut against
the

adjusting
nut,
being careful
not to di-

sturb
the
adjustment. Torque
the
lock-

nut
to
specification
and
remove
the

feeler gauge.

7.
Install
the
clutch return spring.

8. Check
the
free travel
at the
pedal

for conformance
to
specification.
Re-
adjust
if
necessary.

9.
As a
final check, measure
the

pedal free travel with
the
transmission

in neutral
and the
engine running
at

about 3000
rpm. If the
pedal free

travel
at
this speed
is not a
minimum

of
1/2
inch, readjust
the
clutch pedal

free travel. Otherwise,
the
release
fin-

gers
may
contact
the
release bearing

continuously, resulting
in
premature

bearing
and
clutch failure. Free travel

must
be
exactly
to
specification.

CLUTCH ASSIST

SPRING REPLACEMENT

(FAIRLANE, FALCON,

MONTEGO)

1.
Remove
the
cotter
pin
from
the

clutch
rod at the
clutch pedal lever
as-

sembly inside
the
passenger compart-

ment.

2.
Grasp
the
clutch pedal lever

firmly
to
prevent slipping
and
remove

the clutch
rod
from
the
lever. Allow

the clutch pedal lever
to
rest
on the

floor panel.

3.
Remove
the
forward bolt secur-

ing
the
assist spring bracket
to the

brake pedal bracket
and
loosen
the

rear bolt
two or
three turns.
Do not

remove
the
rear bolt.

4.
Grasp
the
assist spring bracket

with pliers
and
rotate upward until
the

spring
can be
separated from
the

bracket.

BRAKE PEDAL

BRACKET

CLUTCH ASSIST SPRING

BRACKET
-
7535

CLUTCH PEDAL

7519
5.
Position
the
assist spring
in the

clutch pedal spring bracket
and the

assist spring bracket. Rotate
the

spring bracket downward until
the

forward bolt holes
in the
assist spring

bracket line
up
with
the
holes
in the

brake pedal bracket
(Fig. 4).

6. Install
the
forward bolt retaining

the assist spring bracket
to the
brake

pedal bracket
and
torque
the
forward

and rear bolts
to
specification.

7.
Install
the
clutch
rod to the

clutch pedal lever
and
insert
the
cotter

pin.

CLUTCH PEDAL, PEDAL

ASSIST SPRING AND/OR

BUSHING REMOVAL

AND INSTALLATION

FORD, MERCURY,

METEOR

1.
Remove
the pin
that secures
the

clutch pedal-to-equalizer
rod to the

clutch pedal.

2.
Grasp
the
clutch pecal lever

firmly
to
prevent slipping
and
remove

the clutch
rod
from
the
lever. Allow

the clutch pedal lever
to
rest
on the

floor.

3.
Loosen
the
lower bolt securing

the assist spring bracket
to the
pedal

support bracket
two or
three turns.

Then, remove
the
upper bolt from
the

bracket.
Do not
remove
the
lower

bolt.

4.
Grasp
the
assist spring bracket

with pliers
and
rotate
it
counterclock-

wise until
the
spring
is
free
(Fig 5).

5.
Remove
the
retaining ring from

the
end of the
clutch pedal shaft. Then

remove
the
shaft, bushings
and
clutch

pedal from
the
support.

6. Remove
the
bushings from
the

pedal shaft
and
pedal support
and

transfer
the
rubber pedal
pad.

7.
After lubricating
the
pedal shaft

ASSIST SPRING

LOWER BOLT

ASSIST SPRING BRACKET-

UPPER
BOL"

C 1769-B

FIG. 4—Clutch Pedal Assembly
—
Fairlane, Montego, Falcon
C2058-A

;. 5—Removing Clutch Assist

Spring
—
Ford,
Mercury and Meteorprocarmanuals.com

05-03-04
Clutch

05-03-04

bushings, position the clutch pedal and

bushings in the pedal support.

8. Install the retaining ring on the

clutch pedal shaft.

9. Position the assist spring in the

pedal support bracket and the assist

spring bracket. Rotate the assist

spring bracket clockwise until the

upper bolt holes line up and install the

bolt. Torque both the upper and lower

bolts to specification.

10.
Check the clutch pedal free

travel and adjust as required.

MUSTANG, COUGAR

1.
Disconnect the battery ground

cable.

2.
Remove the steering column.

Refer to Group 3 of this manual for

the procedure.

3.
Remove the two capscrews re-

taining the master cylinder or booster

to the dash panel. Then remove the

two capscrews retaining the pedal sup-

port bracket to the dash panel.

4.
Working inside the vehicle, dis-

connect the clutch pedal-to-equalizer

rod at the clutch pedal by removing

the retainer and bushing.

5.
Secure the clutch pedal against

the bumper stop with a small C-clamp

as shown in Fig. 6.

6. Disconnect the stop light switch

wires at the connector.

7.
Remove the switch retainer and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin.
Remove the master cylinder push

CLUTCH PEDAL ASSIST SPRING
rod, bushing and nylon washer from

the brake pedal pin.

8. Remove the screw retaining the

pedal support bracket to the top inner

cowl bracket (Fig. 6).

9. Remove the two sheet metal

screws retaining the pedal support

bracket to the dash panel.

10.
Remove the two screws retain-

ing the pedal support bracket to the

upper cowl brace and lower the pedal

support bracket away from the steer-

ing column studs.

11.
Remove the pedal support

bracket assembly from the vehicle.

12.
Mount the bracket in a vise.

13.
Remove the small C-clamp se-

curing the clutch pedal to the bumper.

Slowly pivot the pedal away from the

bumper until the assist spring can be

lifted from its seat.

14.
Remove the retainer clip from

the clutch and brake pedal shaft.

Then, remove the clutch pedal and

shaft assembly, brake pedal assembly,

and bushings from the pedal support

bracket.

15.
Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

brake and clutch pedal assemblies.

16.
Position the brake pedal to the

pedal support bracket. Install the

clutch and brake pedal shaft through

the pedal support and brake pedal as-

sembly. Install the retainer.

17.
Install the clutch pedal assist

spring and pivot the pedal against its

bumper stop. Secure the pedal against

the bumper with a small C-clamp as

TOP INNER COWL-TO-BRACKET

RETAINING SCREW

C2057-A

FIG.
6—Clutch
Pedal —Mustang and Couga?
shown in Fig. 6.

18.
Position the pedal support

bracket assembly to the dash panel

and to the steering column retainer

studs.

19.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two sheet metal screws.

20.
Install the two capscrews at-

taching the pedal support bracket to

the upper cowl bracket.

21.
Install the screw attaching the

support bracket to the top inner cowl

bracket (Fig. 6).

22.
Install the inner nylon washer,

bushing master cylinder push rod on

the brake pedal pin. Position the stop

light switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, and install

the outer nylon washer. Secure with

the self-locking pin.

23.
Connect the stop light switch

wires to the connector and install the

wires to the retaining clip.

24.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and retain-

er and remove the C-clamp from the

bracket.

25.
Working from the engine side

of the dash panel, install the two cap-

screws attaching the pedal support

bracket to the dash panel. Then install

the two screws attaching the master

cylinder to the dash panel.

26.
Install the steering column.

Refer to Group 3 of this manual for

the procedure.

27.
Adjust the clutch pedal free

travel.

28.
Check the brake pedal free

height and travel measurements

(Group 2).

29.
Connect the battery ground

cable.

CLUTCH PEDAL AND/OR

BUSHING REMOVAL

AND INSTALLATION

MOM EGO, FALCON

FAIRLANF

1.
Remove the retaining clip (Fig.

2) that secures the equalizer rod to the

clutch pedal. Disconnect the rod from

the pedal.

2.
Remove the lower bolt retaining

the assist spring bracket to the pedal

support. Then, loosen the upper

bracket retaining bolt (approximately

4 turns) and disconnect the spring

from the clutch pedal and bracket.

3.
Disconnect the brake pedal push

rod from the brake pedal.procarmanuals.com

05-03-05
Clutch

05-03-05

4.
Remove the bolt that secures the

left air vent control cable bracket to

the instrument panel. Position the

control cable to one side.

5.
Remove the retaining clip and

flat washer from the clutch pedal

shaft. Then, remove the shaft, bush-

ing, clutch pedal and brake pedal

from the support.

6. Remove the bushings from the

pedal shaft, and transfer the pedal

pad.

7.
Lubricate the clutch pedal shaft

bushings and position them on the

shaft. Then, position the brake pedal

and clutch pedal in the pedal support.

8. Install the flat washer and re-

taining clip on the pedal shaft.

9. Position the assist spring to the

pedal and bracket. Pry the bracket

forward and install the lower bolt.

Torque the bolts to specifications.

10.
Position the master cylinder

push rod, bushing, and washers on the

brake pedal and secure with a retain-

ing clip.

11.
Connect the equalizer rod to

the clutch pedal and secure it in place

with a retaining clip.

12.
Position the air vent control

cable bracket to the instrument panel

and secure with the attaching bolt.

13.
Adjust the clutch pedal free

travel.

EQUALIZER BAR AND/OR

BUSHING REMOVAL AND

INSTALLATION

FORD, MERCURY

AND METEOR

1.
Raise the vehicle and disconnect

the clutch pedal-to-equalizer rod at

the equalizer bar (Fig. 1).

2.
Disconnect the return spring and

retaining spring at the release lever.

Separate the release lever rod from

the release lever.

3.
Remove the equalizer bar frame

bracket from the frame.

4.
Remove the equalizer bar from

the pivot on the flywheel housing.

5.
Remove the wire clip to replace

the outer bushing and the snap ring
from the inner pivot stud to replace

the inner bushing.

6. Position the flat washer, felt

washer and bushing on the inner and

outer pivots. Secure these parts with

the snap ring.

7.
Position the equalizer bar on the

inner pivot and bolt the equalizer bar

frame bracket to the frame. Torque

the attaching bolts to specification.

8. Install the clutch release rod, re-

turn spring and retaining spring.

9. Connect the clutch pedal rod to

the equalizer bar.

10.
Adjust the clutch pedal free

travel.

MUSTANG, COUGAR,

MONTEGO, FALCON,

FAIRLANE (EXCEPT

MONTEGO AND FAIRLANE

WITH 390 V-8)

1.
Disconnect the clutch pedal

equalizer rod at the equalizer bar

(Figs.
2 and 3).

2.
Raise the vehicle and disconnect

the release lever, return spring at the

lever.

3.
Remove the equalizer bar outer

bracket and bushing assembly.

4.
Remove the release rod from the

equalizer bar, and then remove the

equalizer bar. Remove the bushing

and washers from the inner mounting

stud.

5.
Position the equalizer bar, wash-

ers,
inner bushing, and retainer on the

inner stud.

6. After positioning the outer bush-

ing, install the outer bracket (with the

equalizer bar in place).

7.
Connect the release rod and the

release lever return spring.

8. Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer baY and secure with the re-

taining pin.

9. Adjust the clutch pedal free trav-

el as required.

MONTEGO AND

FAIRLANE—390 V-8

1.
Disconnect the clutch pedal
equalizer rod at the equalizer bar (Fig.

2).

2.
Raise the vehicle and disconnect

the return spring at the release lever.

Disconnect the release lever rod from

the equalizer lever.

3.
Remove the equalizer bar center

bolt.

4.
Separate the equalizer bar and

remove both sections from the vehicle.

5.
Remove the bolts retaining the

equalizer bar inner bracket to the fly-

wheel housing and remove the bracket

and bushing assembly.

6. Remove the equalizer bar outer

bracket and bushing assembly.

7.
Remove the snap ring, bushing,

and felt washer from each bracket as-

sembly.

8. Position a felt washer, and bush-

ing on each bracket assembly and se-

cure with the snap ring.

9. Install the outer bracket and

bushing assembly to the frame (Fig.

2).
Torque the bracket attaching bolts

to specifications.

10.
Position the outer section of the

equalizer bar on the outer bracket

pivot.

11.
Connect the two sections of the

equalizer bar. Insert the inner bracket

pivot into the equalizer bar and install

the assembly to the flywheel housing.

Torque the attaching bolts to specifi-

cations.

12.
Install the equalizer bar center

bolt and torque to specifications.

Make sure that both ends of the

equalizer bar are against the felt

washers.

13.
Connect the release rod and the

release lever return spring.

14.
Adjust the clutch pedal free

travel.

15.
Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer bar and secure with the re-

taining clip.

16.
Check the free travel at the

pedal for conformance to specifica-

tions.
Readjust if necessary.

REMOVAL AND INSTALLATION

CLUTCH REMOVAL

1.
Raise the vehicle on a hoist.

2.
Disconnect the drive shaft from

the rear U-joint flange. Then, slide the

drive shaft off the transmission output

shaft. Insert the appropriate tool over

the output shaft and into the extension

housing oil seal.
3.
Disconnect the speedometer

cable from the extension housing.

4.
Disconnect the gear shift rods

from the transmission. If the vehicle is

equipped with a four-speed transmis-

sion, remove the bolts that secure the

four-speed transmission, disconnect

the front brake cable from the cross-

member and remove the crossmem-
member from the vehicle.

5.
Remove the bolts that attach the

transmission to the flywheel housing.

6. Move the transmission rearward

until the input shaft clears the fly-

wheel housing, then remove it from

the vehicle.

7.
Disconnect the clutch release

lever retaining spring from the release

lever.procarmanuals.com

05-03-06
Clutch

05-03-06

8. Remove the starter cable then

remove the starter motor from the fly-

wheel housing.

9. Remove the bolts that secure the

engine rear plate to the front lower

part of the flywheel housing.

10.
Remove the flywheel housing

lower cover (390 CID housing only).

11.
Remove the bolts that attach

the housing to the cylinder block.

12.
Move the housing back just far

enough to clear the pressure plate,

then move it to the right to free the

pivot from the clutch equalizer bar. Be

careful not to disturb the linkage and

assist spring.

13.
Loosen the six pressure plate

cover attaching bolts evenly to release

the spring tension. If the same pres-

sure plate and cover is to be installed

after the clutch is overhauled, mark

the cover and flywheel so that the

pressure plate can be installed in the

same position.

14.
Remove the pressure plate and

the clutch disc from the flywheel.

CLUTCH INSTALLATION

1.
Install the clutch release lever if

it was removed.

2.
Place the clutch disc, and pres-

sure plate assembly in position on the

flywheel. Start the cover attaching

bolts to hold the pieces in place, but

do not tighten them. Avoid touching

the clutch disc facing, dropping the

parts or contaminating them with oil

or grease as clutch chatter may result.

3.
Align the clutch disc with the

tool shown in Fig. 7, and alternately

tighten the bolts a few turns at a time

until they are all tight. Then torque

the six pressure plate cover attaching

bolts to specification before removing

the tool.
4.
Apply a light film of grease

(C3VY-19586-A) to the outside diam-

eter of the transmission front bearing

retainer. Apply a light film of grease

(C3VY-19586-A) to both sides of the

release lever fork where it contacts the

release bearing bore spring clips.

Apply a light film of grease to the re-

lease bearing surface that contacts the

pressure plate release fingers. Fill the

grease groove of the release bearing

hub with lithium base grease (C3VY-

19586-A). Clean all excess grease

from inside the bore of bearing hub.

Excess grease will be forced onto the

spline by the transmission input shaft

bearing retainer and will contaminate

the clutch disc. Also, place the release

bearing and hub on the release lever.

5.
Make certain that the flywheel

housing and the cylinder block mount-

ing surfaces are clean. Position the

felt washer on the pivot in the fly-

wheel housing. Slip the pivot into the

clutch equalizer shaft being careful

not to disturb the linkage and at the

same time position the housing on the

dowels in the cylinder block. Install

and torque the attaching bolts to spec-

ification.

6. Install the starting motor and

connect the cable.

7.
The mounting surfaces of the

transmission and the flywheel housing

must be free of dirt, paint, and burrs.

Install two guide pins in the flywheel

housing lower mounting bolt holes.

Move the transmission forward on the

guide pins until it is tightly positioned

against the flywheel housing.

8. Install the two upper mounting

bolts.
Then, remove the guide pins

and install the two lower mounting

bolts.
Torque all the bolts to specifica-

tion.

9. Raise the rear of the engine and
install the crossmember. Install and

torque the crossmember attaching

bolts to specifications, then lower the

engine.

10.
Install the extension housing-

to-engine rear support attaching bolts.

Torque the bolts to specification.

11.
Remove the transmission jack

and connect the parking brake cable.

12.
If the vehicle is equipped with a

four-speed transmission, connect the

gear shift linkage control bracket to

the extension housing.

13.
Connect the gear shift rods to

the transmission. Adjust the shift link-

age as required.

14.
Connect the release lever retain-

ing spring. Install the flywheel housing

cover (390 CID housing only).

15.
Remove the tool from the

transmission output shaft and install

the drive shaft.

16.
Check the clutch pedal free

travel.

CLUTCH ARBOR CLUTCH DISC

PRESSURE PLATE

C 1788-A

FIG. 7—Installing Clutch Disc —

Typicalprocarmanuals.com

05-04-01
Specifications

05-04-01

PART
5-4
Specifications

CLUTCH IDENTIFICATION

Car Line

Ford

Meteor

Ford

Ford

Meteor

Ford

Meteor

Mercury

Ford

Falcon

Fairlane

Falcon

Montego

Fairlane

Montego

Falcon

Mustang

Mustang

Cougar

Fairlane

Montego

Fairlane

Montego

Mustang

Cougar

Fairlane

Montego

Mustang

Cougar

Fairlane

Montego

Mustang

Cougar
Engine

240-IV

240-IV

302-2V

390-2V,

4V

429-4V

170-1V

200-IV

250-1V

302-2V

200-IV

250-1V

302-2V

390-2V,

4V

390-4V GT

351-2V,

4V

428-4V
Transmission

3-Speed

3-Speed

Heavy Duty

3-Speed

3-Speed

4-Speed

4-Speed

3-Speed

3-Speed

3-Speed

4-Speed

3-Speed

3-Speed

4-Speed

3-Speed

4-Speed

3-Speed

4-Speed

3-Speed

4-Speed

4-Speed
Pressure Plate

Diameter

(Inches)

9.5

11

10

11

11.5

9

9

10

9

10

11

11.5

11

11.5
No.
of

Springs

6

9

9

9

12

6

6

9

6

9

9

12

9

12
Color Identification

(Paint Daub)

Pressure Plate-No Color

Cover—Green

Springs—Aluminum

Pressure Plate-White

Cover-Pink and Blue

Springs
8-Green

Pressure Plate-Green

Cover-White

Springs-White
on
Bronze

Pressure Plate—Orange

Cover-Black

Springs-Aluminum

Pressure Plate-Yellow

Cover-Black

Springs-Green

Pressure Plate-Orange

Cover—Purple

Springs-Aluminum Stripe

Pressure Plate-Orange

Cover-Purple

Springs-Aluminum Stripe

Pressure Plate—Green

Cover-White

Springs-Bronze

Pressure Plate—Orange

Cover—Purple

Springs—Aluminum Stripe

Pressure Plate-Blue

Cover—Purple

Springs—Bronze

Pressure Plate-Green

Cover-Purple

Springs-Purple

Pressure Plate-Green

Cover-Purple

Springs-Purple

Pressure Plate-Blue

Cover-Yellow

Springs-Silver

Pressure Plate-Yellow

Cover-Black

Springs—Green
Disc

Diameter

(Inches)

9.5

11

10

11

11.5

9

9

10

9

10

11

11.5

11

11.5
No.
of

Springs

6

8

12

12

10

6

6

12

6

6

8

8

8

10
Color Identification

(Paint Daub)

Clutch-Yellow

Springs—2 Purple (Small)

4 Aluminum (Large)

Clutch-No Color

Springs—4 Aluminum

4 Pink

Clutch-Blue

Springs-6 Orange (Small)

6 Pink (Large)

Clutch-Pink

Springs-6 Green (Small)

6 Orange (Large)

Clutch-Gray

Springs—5
Red
Stripe (Small)

5
No
Color (Large)

Clutch-Pink

Springs—Blue

Clutch-Pink

Springs-Blue

Clutch-Blue

Springs-6 Pink

6 Orange

Clutch-Blue

Springs—Blue

Clutch-Green

Springs-Orange

Clutch-Pink
and
Orange

Springs—Aluminum

Clutch-Pink and Orange

Springs—Aluminum

Clutch—Pink and Orange

Springs—Aluminum

Clutch-Gray

Springs-Red Stripe

CLUTCH-DRIVELINE ADJUSTMENTS (INCHES)

Release Lever
Rod
Adjusting
Nut to
Swivel Sleeve

Ford,
Mercury Meteor
0.194

Fairlane, Montego, Falcon, Mustang, Cougar
ex.
with

390,
428
engine
0.136

390,
428
Engines
0.178
*

Clutch Pedal Free Travel (Engine Running)
7/8"-l
1/8"

Clutch Housing Alignment
If
Dia-L-lgner reading
0.014

is greater than that indicated,
the
clutch

housing alignment
is
unacceptable.

Maximum Shim to Correct Alignment
0.010procarmanuals.com

05-04-02

Specifications

05-04-02

TORQUE LIMITS (FT-LBS)

Description

Lower Access Clutch Cover Pan to Flywheel Housing Bolts (Cast Iron Housing)

Transmission Assembly to Flywheel Housing Bolts

Pressure Plate and Cover Assembly to Flywheel Attaching Bolts

Clutch Release Equalizer Frame Bracket Bolts

Clutch Pedal Free Travel Adjustment Nut

Flywheel Housing to Cylinder Block Bolts
6-Cylinder

8-Cylinder

Clutch Pedal Assist Spring Bracket to Brake Pedal Support Bracket
Meteor

Ford,
Mercury

17-20

37-42

12-20

15-24

15-20

_

12-17
Mustang,
Cougar

Fairlane, Montego, Falcon

-

-

12-20

15-24

15-20

23-33

40-50

12-17

SPECIAL TOOLS

Tool No.

A-37H

T61L-7657-Aor B

T57L-7657-A

T64P-7657-A
Description

Clutch Disc Aligner-Universal

Transmission Extension Housing Oil Seal

Replacer
Tool No.

CJ91B

T64L-6392-A

T49P-7580-A
Description

Universal Joint Bearing Replacer

Dia-L-lgner Gauge

Clutch Release Bearing Replacerprocarmanuals.com

06-01-03

General Transmission Service

06-01-03

chipped, broken or worn.

11.
Check the synchronizer sleeves

for free movement on their hubs.

Make sure that the alignment marks

(etched marks) are properly indexed.

12.
Inspect the synchronizer block-

ing rings for widened index slots,

rounded clutch teeth and smooth in-

ternal surfaces (must have machined

grooves). With the blocker ring on the
cone,
the distance between the face of

the blocker ring and the clutch teeth

on the gear must not be less than

0.010 inches.

13.
Replace the speedometer drive

gear if the teeth are stripped or dam-

aged. Make certain to install the cor-

rect size replacement gear.

14.
Replace the output shaft if

there is any evidence of wear or if any
of the splines are damaged.

15.
Inspect the bushing and the seal

in the extension housing. Replace

them if they are worn or damaged.

The bushing and/or seal should be re-

placed after the extension housing has

been installed on the transmission.

16.
Replace the seal in the input

shaft bearing retainer.

17.
Replace the seals on the cam

and shafts.procarmanuals.com