Section 08-01: Clutch/Pressure Plate | 1996 F-150, F-250, F-350, F-Super Duty Chassis Cab and Bronco Equipped with Manual Transmission Workshop Manual |
| Description | Tool Number |
|---|---|
| Clutch Coupling Tool | T88T-70552-A |
Removal
Disconnect the battery negative cable.
Remove external clutch slave cylinder or hydraulic line quick disconnect on concentric clutch slave cylinder applications, using Clutch Coupling Tool T88T-70552-A.
Remove clutch release lever, if equipped.
Remove dust cover, if equipped.
Remove the transmission (7003) from the vehicle. Refer to appropriate section in Group 07.
Mark the assembly position of clutch pressure plate (7563) and cover to flywheel (6375) if the original clutch components are to be installed.
Remove clutch pressure plate, cover assembly and clutch disc (7550) from flywheel. Remove the transmission input shaft pilot bearing only if replacement is needed.
Installation
CAUTION: The 7.3L cover assembly bolt is 5/16 inch x 18 x 0.75 inch while the 7.5L MFI cover bolt is 5/16 inch x 18 x 0.92 inch. The 0.92-inch bolt cannot be used with the dual mass flywheel because it will extend beyond the inner surface of the secondary flywheel and interfere with the primary flywheel. Only the 0.75-inch cover bolt can be used with the dual mass flywheel.
Position clutch disc on flywheel so Truck Clutch Alignment Shaft D79T-7550-A or equivalent can enter clutch transmission input shaft pilot bearing to align disc.
Position clutch pressure plate and cover assembly on flywheel.
Align clutch pressure plate and clutch disc, and install the retaining bolts that fasten assembly to flywheel.
If installing original clutch components, use the location marks made during removal. Tighten the retaining bolts to specifications. Refer to Specifications at the end of this section.
On 7.3L diesel and 7.5L gasoline engines (6007), clean and lubricate the following:
Install the transmission. Refer to appropriate section in Group 07.
Position clutch release lever, if equipped, into clutch release hub and bearing (7548) and align with clutch release lever stud. Push upward on clutch release lever until snapped into position.
Install clutch release lever dust shield (7513), if equipped.
Install the external clutch slave cylinder (7.3L or 7.5L engine), or attach hydraulic tube quick connect fitting (4.9L, 5.0L or 5.8L engine).
NOTE: When the battery (10655) has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Connect battery negative cable.
Operate vehicle to check clutch operation.
| Item | Part Number | Description |
|---|---|---|
| 1 | 6375 | Flywheel |
| 2 | 7563 | Clutch Pressure Plate |
| 3 | 7003 | Transmission |
| 4 | 7A508 | Clutch Slave Cylinder |
| 5 | N605907-S101 | Bolt, M8-1.25 x 30 |
| 6 | 387299-S2 | Bolt, 3/8-16 x .97 (11-Inch) |
| 7 | 34792-S2 | Washer |
| 8 | 7550 | Clutch Disc |
| 9 | 7118 | Transmission Input Shaft Pilot Bearing |
| A | — | Tighten to 19-26 Nm (14-19 Lb-Ft) |
| B | — | Tighten to 30-40 Nm (22-30 Lb-Ft) |
| Item | Part Number | Description |
|---|---|---|
| 1 | — | Flywheel Dowel (Part of 6477) |
| 2 | 7118 | Transmission Input Shaft Pilot Bearing |
| 3 | 7550 | Clutch Disc |
| 4 | 7563 | Clutch Pressure Plate |
| 5 | 7548 | Clutch Release Hub and Bearing |
| 6 | 7513 | Clutch Release Lever Dust Shield |
| 7 | 7515 | Clutch Release Lever |
| 8 | 391070-S100 | Bolt, 5/16 x 18 x .75 (8 Req'd) (7.3L) |
| 9 | 389572-S2 | Bolt, 5/16 x 18 x .92 (8 Req'd) (7.5L) |
| 10 | 7007 | Engine Rear Plate |
| 11 | 56519-S2 | Bolt, 5/16 x 18 |
| 12 | 6477 | Flywheel, 7.3L |
| 13 | 6375 | Flywheel, 7.5L |
| 14 | 6397 | Flywheel Housing to Block Dowel, 7.5L |
| 15 | 7B602 | Clutch Release Lever Stud |
| A | — | Tighten to 26-35 Nm (19-26 Lb-Ft) (7.3L) |
| B | — | Tighten to 19-26 Nm (14-19 Lb-Ft) (7.5L) |
| C | — | Tighten to 11-15 Nm (8-11 Lb-Ft) |