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A. Penland
A. Penland, Ford Senior Master Technician, ASE
Category: Ford
Satisfied Customers: 6642
Experience:  ASE Master Certified, ASE Advanced Gasoline Engine Performance
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how to put a clutch on a 94 ford ranger

Customer Question

how to put a clutch on a 94 ford ranger
Submitted: 8 years ago.
Category: Ford
Expert:  A. Penland replied 8 years ago.
REMOVAL AND INSTALLATION

Disc and Pressure Plate

SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Clutch Coupling Tool T88T-70522-A
Clutch Aligner T74P-7137-K

Removal

  1. Disconnect the battery negative cable.

  1. Disconnect clutch hydraulic system master cylinder push rod from clutch pedal (7519).

  1. Raise the vehicle on a hoist and position suitable safety stands under vehicle.

  1. Remove starter motor (11001).

  1. Disconnect the hydraulic coupling at transmission with Clutch Coupling Tool T88T-70522-A. Slide the white plastic sleeve toward clutch slave cylinder, and apply a slight tug on tube.

  1. Remove transmission (7003). Refer to Section 07-03 .

  1. Check pressure plate finger height variations before removing.



    Clutch Disc and Clutch Pressure Plate, Ranger 2.3L and 3.0L





    Item Part Number Description
    1 6375 Flywheel
    2 7003 Transmission
    3 7A508 Clutch Slave Cylinder
    4 N605905-S Bolt
    5 7563 Clutch Pressure Plate
    6 N802096-S2 Bolt
    7 7550 Clutch Disc
    8 7118 Transmission Input Shaft Pilot Bearing
    9 7K578 Flywheel Dowel Pin
    A - Tighten to 19-26 Nm
    (14-19 Lb-Ft)
    B - Tighten to 21-32 Nm
    (15-24 Lb-Ft)
  1. Mark assembly position of clutch pressure plate (7563) and cover to flywheel (6375) if installing original components.

  1. CAUTION: If cover and plate are to be reinstalled, bolts must be removed evenly or permanent damage to diaphragm spring will occur causing clutch to not release fully.

    Loosen clutch pressure plate and cover attaching bolts evenly in a star pattern until clutch pressure plate diaphragm spring is expanded. Remove bolts.

  1. Remove clutch pressure plate and clutch disc (7550) from flywheel.





Installation

  1. NOTE: Clean clutch pressure plate and flywheel with a suitable commercial alcohol base solvent so surfaces are free from any oil film.

     

     

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

     

     

    NOTE: The clutch disc and pressure plate should always be replaced as a set.

     

     

    Position clutch disc on flywheel so Clutch Aligner T74P-7137-K can enter clutch transmission input shaft pilot bearing (7118) and align clutch disc.



    Clutch Wear Indicator








  1. When installing original clutch pressure plate and cover, align assembly and flywheel with marks made during removal and with dowels on flywheel.

  1. Position clutch pressure plate and cover on flywheel and dowels. Align the clutch pressure plate and clutch disc.

  1. Install assembly bolts to flywheel. Tighten bolts to 21-32 Nm (15-24 lb-ft) uniformly in sequence shown.

  1. Remove clutch aligner tool.





  1. Install transmission. Refer to Section 07-03 .

  1. Connect coupling by pushing the male coupling into female coupling of clutch slave cylinder.

  1. Connect hydraulic clutch master cylinder push rod to clutch pedal.

  1. NOTE: When the battery 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 10 miles or more to relearn the strategy.

     

     

    Connect battery negative cable.

  1. Bleed clutch system if required. Refer to Section 08-02 .


Expert:  A. Penland replied 8 years ago.

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Here are the pictures that didn't make it on the last posting.