Ford BR3Z-7B546-AE Clutch Assembly

Getting to most parts of the clutch is performed with the transmission out of the car but the engine stays in place. If the engine is going to be pulled for a major rebuild, the clutch should also be inspected for wear and any worn parts should be replaced, since the cost of clutch parts is quite low and it is cheaper to replace the clutch whenever the engine or transmission is pulled unless the clutch is new or in very good condition. First, remove the transmission and then assist the engine from above using a fixture or hoist in order to lift the engine. The release bearing can now be left rigid affixed to the transmission housing. When removing the clutch disc, there is usually some pressure required to support the clutch disc and this can be applied by using a clutch alignment tool through the clutch disc hub. There may be indexing marks missing on the flywheel or pressure plate and if so the marks need to be scribed or painted before the parts are refitted. Unlubricated: loosen the pressure plate-flywheel bolts in a star like pattern to reduce the pressure of the spring then dismantle the bolts, pressure plate and clutch disc, the bolts are discarded for new ones during reassembly. Check all parts with special attention to the flywheel for an external possibility of cracks or defects; machine the flywheel if required. In particular, examine the clutch disc lining to assess its wear: it should protrude 1116 inch above the rivet heads and cannot have any distortion. It is advised that the release bearing and release cylinder must also be renewed together with the clutch disc. Check to see if pressure plate is worn or damaged beyond measure and should be replaced, and examine the pilot bearing for the same and should be replaced if damaged. When placing a new pilot bearing its surface should be coated with a thin layer of oil and then forced into its cavity with the seal end towards the transmission. Remove any oil or grease from the flywheel and pressure plate surfaces before fitting and ensure these are clean before reassembly. Insert the clutch disc and the pressure plate to the flywheel so that they would be properly positioned with the help of the alignment tool. Screw in the new pressure plate-to-flywheel bolts lightly and then torque the clutch disc to the central of the fly which will eliminate distortion of the pressure plate. Last but not the least fix the clutch release bearing and release cylinder and finally fix the transmission along with all other parts which were removed earlier.