Ford 7L5Z-7563-B
Pressure Plate

Starting clutch disc and pressure plate replacement requires first removing the transmission unit. The installation of clutch disc and pressure plate requires even bolt removal to avoid damaging the diaphragm spring and causing complete clutch release failure. Index-marking of the clutch pressure plate to the flywheel requires completion before removing six bolts and the clutch pressure plate and clutch disc. Check the transmission pilot bearing for any abnormal alignment or looseness from the crankshaft or flywheel as well as scoring and discoloration along with wear and broken rollers and damage to the seals and lubricant leakage. If any problems exist, replace the pilot bearing. Use emery cloth to smooth out minor defects on the clutch disc friction surface then check it for grease and oil saturation before examining rivets for wear and looseness as well as springs for breakage and spline rust and wear. Replace the clutch disc if necessary. A suitable solution should be used to clean the clutch pressure plate friction surface before inspecting lever wear and checking the friction surface for any scoring, burning, heat checking, distortion, warping or dishing that would require pressure plate replacement. Test the clutch flywheel surface with coarse emery cloth or 400 grit sandpaper using machine line direction when repairing minor defects and checking for surface flaws and heat checks along with glazing, scoring, scratches or grooves. Internal inspection of the flywheel or ring gear needs to verify the absence of any broken or worn or chipped teeth. Begin by greasing the transmission pilot bearing after which adjust the clutch pressure plate by finger pressure until the adjusting ring becomes free so you can turn the ring clockwise to compress tension springs and stay in position once you release finger pressure. A clutch aligner tool should be used to place the clutch disc on the flywheel while matching the markings originally created for reuse of the pressure plate and flywheel units. The clutch disc together with the pressure plate must be positioned correctly using the aligner before you fasten six bolts by using torque settings of 27 Nm (20 lb-ft) following a cross pattern. Secure the transmission to the engine only after connecting the hydraulic tube to the clutch slave cylinder.

The first step for clutch disc and pressure plate repair requires the transmission removal. Any future installation of the clutch disc and pressure plate needs careful bolt removal balance to avoid breaking the diaphragm spring that could cause total clutch release failure. Before removing clutch pressure plate bolts and disc alongside pressure plate, mark the clutch pressure plate to flywheel so the parts can be reinstalled. The transmission input shaft pilot bearing needs inspection for misalignment and looseness next to the crankshaft (gasoline engine) or flywheel (diesel engine) along with examination of scoring and discolored, worn-out, broken rollers, and seal damage that might lead to lubricant leakage; therefore, replace the bearing if any defects appear. Emery cloth should be employed to polish away small imperfections on clutch disc friction surfaces and inspection should be made for oil and grease saturation as well as worn or loose rivets at the hub and broken springs and worn or rusted splines which require clutch disc replacement. Check the friction surface of the clutch pressure plate with a proper cleaning solution before evaluating lever wear levels, friction surface distress, and looking for scoring along with burning heat effect, distortion, warpage, and dish formation; replace the clutch pressure plate if any such issues are present. Address any surface disorders on the flywheel clutch through appropriate cleaning methods followed by checking for heat checks and surface cracks as well as glazing and scoring and scratches and grooves; minor issues can be corrected by sanding the surface parallel to machine lines using coarse emery cloth or fine-grade (400 grit) sandpaper. A thorough inspection of the flywheel or ring gear should identify any damages to the teeth. The procedure for installation includes applying grease to the transmission input shaft pilot bearing before performing clutch pressure plate adjustment through finger pressure that lets the adjusting ring move freely while turning this ring counterclockwise to spring tension compression followed by finger pressure release to maintain reset alignment. An adequate clutch aligner assists in properly positioning the clutch disc on the flywheel and you should align any marks made during removal when using an existing clutch pressure plate and flywheel. Position the clutch components on the aligner before screwing in their connecting bolts according to a star pattern and tightening to 27 Nm (20 lb-ft). Install the transmission first and then proceed with connecting the clutch slave cylinder hydraulic line before fixing the transmission to the engine.