Ford Mustang (1999-2004) Service Manual: Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines

Ford Mustang (1999-2004) Service Manual / Manual Transmission, Clutch and Transfer Case / Clutch / Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines

Special Tool(s)

Clutch Aligner 308-020 (T74P-7137-K)

Material

Item Specification
Premium Long Life Grease XG-1-C ESA-M1C75-B

1. Remove the transmission.

2. CAUTION: Loosen the bolts evenly to prevent clutch pressure plate damage.

NOTE: If the parts are to be reused, mark the clutch pressure plate and the flywheel.

Remove the bolts and remove the clutch pressure plate and the clutch disc.

Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines

Installation

NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol-based solvent so surfaces are free from oil film.

Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in the solvent.

1. Position the clutch disc on the flywheel.

  • Using the special tool, align the clutch disc.

Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines

2. NOTE: If reusing the clutch pressure plate, align the plate using the marks made during removal.

Using the special tool, align the clutch pressure plate and install it on the dowels.

  • Install the bolts in the sequence shown.
  • Remove the special tool.

Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines

 

Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines

3. NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input shaft must be cleaned and lubricated with grease.

Install the transmission.

    Clutch (Description and Operation)
    The primary function of the clutch is to couple and uncouple engine power to the transmission upon driver command. The clutch is a single plate, dry friction clutch disc. The clutch disc ha ...

    Disc and Pressure Plate - 4.6L (4V) Engine
    Special Tool(s) Clutch Aligner 308-020 (T74P-7137-K) Material Item Specification Premium Long Life Grease XG-1-C ESA-M1C75-B 1. Disconnect the battery ground cable. ...

    Other materials:

    Removal
    1. Remove the roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the LH timing chain for the LH side and both timing chains for the RH side. For additional information, refer to Timing Drive Components in this ...

    Output Shaft
    Special Tool(s) Pinion Bearing Cone Remove 205-D002 (D79L-4621-A) or Equivalent Spiral Snap Ring Replacer 308-096 (T85P-7025-A) Disassembly 1. Using the special tool and a press, remove the third/fourth gear synchronizer asse ...

    Fittings - R-Clip
    Material Item Specification SAE 5W-20 Super Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C153- H Disconnect WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel- ...