Ford Mustang (1999-2004) Service Manual: Disc Check

Special Tool(s)

Brake/Automobile Brake Drum System with Vacuum 164-R3622 or equivalent
Dial Indicator/Magnetic Base 100-D002 (D78P-4201-B) or equivalent

WARNING: Dust and dirt present on wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to health when made airborne by cleaning with compressed air or by dry brushing. Failure to follow these instructions may result in personal injury.

WARNING: Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as the brake automobile brake drum system with vacuum. Dust and dirt from the vacuum should be disposed of in a manner that prevents dust exposure such as sealed bags. The bag must be labeled according to OSHA instructions and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury.

WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury.

WARNING: Grinding or sanding on the brake linings, pads, rotors, drums or clutch facings should be done only while using correct exhaust-ventilated equipment. Failure to follow these instructions may result in personal injury.

WARNING: OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with carrying out brake or clutch service should be present in the area. Failure to follow these instructions may result in personal injury.

1. Check the clutch disc lining surface for hardening or the presence of oil.

2. Check for a worn clutch disc lining. Measure the minimum allowable depth to the rivet heads with a slide caliper.

Disc Check

3. Check for loose clutch disc lining rivets.

4. Use the special tool to check the maximum allowable runout of the clutch disc.

Disc Check

5. Use an emery cloth to remove minor imperfections in the clutch disc lining surface.

Disc Check

6. Check for wear or rust on the splines. If necessary, clean them with an emery cloth.

7. Check the clutch disc (7550) for cracking, scoring, discoloration or other surface marks. Install a new clutch disc as necessary.

    Manual Transmission and Clutch (Diagnosis and Testing)
    Inspection and Verification It is important to get an accurate description of the concern before any diagnosis can be carried out. Ask questions as to whether it occurs when hot or cold, durin ...

    Pressure Plate Check
    1. Check the clutch pressure plate surface for scoring, cracks or discoloration. Minor scratches or discoloration should be removed with a fine emery cloth. 2. Measure the flatness of the clutch ...

    Other materials:

    Changing a bulb
    Lamp Assembly Condensation Exterior lamps are vented to accommodate normal changes in pressure. Condensation can be a natural by-product of this design. When moist air enters the lamp assembly through the vents, there is a possibility that condensation can oc ...

    Power seats
    WARNING: Never adjust the driver’s seat or seat back when the vehicle is moving. WARNING: Before returning the seat back to its original position, make sure that cargo or any objects are not trapped behind the seat back. The power seat control is located on ...

    Axle Housing
    Removal and Installation 1. CAUTION: The vehicle must be on level ground and at curb height. Mark the rear shock absorbers relative to their protective sleeve.  During installation, raise the suspension to this reference mark before tightening the s ...