OEM 2008 Ford F-250 Super Duty Clutch Disc

2008 Ford F-250 Super Duty Clutch Disc Parts Q&A

• Q: How to service and repair the clutch disc and pressure plate for 5.4L, 6.8L, and 6.4L engines on 2008 Ford F-250 Super Duty?

  A: A professional must detach the transmission first to service and fix the clutch disc and pressure plate used in 5.4L, 6.8L, and 6.4L engines. Index all clutch pressure plate and flywheel surfaces when you plan to reuse them. First remove all clutch pressure plate bolts followed by the clutch pressure plate accompanied by the clutch disc. Your inspection of the transmission input shaft pilot bearing should reveal correct alignment and all clearances while avoiding scoring, discoloration or wear of the components along with broken rollers and seal damage that requires replacement. Emery cloth cleans any minor surface issues from the clutch disc friction layer before checking it for saturated oil and examining the rivets for wear and broken springs and spline wear which indicates disc replacement. The clutch pressure plate friction surface requires cleaning with appropriate solution before inspectors check the levers for wear and friction surface for scoring and burning and replacements must occur when conditions are detected. The necessary cleaning of the flywheel clutch surface provides the opportunity to identify cracks, heat checks and glazing, scoring and scratches until anyone with coarse emery cloth or 400 grit sandpaper can smooth the surface parallel to machine lines. Verify that the ring gear has no missing or fractured teeth. Apply Krytox® High-Temperature Grease to the transmission input shaft pilot bearing before installation especially when transmission removal required suction of lubrication. To reset the wear indicator of the original clutch pressure plate start by pressing on the fingers to free up the adjusting ring which allows movement before rotating it counterclockwise to compress the tension springs and then keeping the pressure released at the reset position. Set the clutch disc onto the flywheel followed by alignment using a clutch alignment tool which determines that 6.8L and 5.4L engines need 1-1/4 in input shafts but 6.4L engines require 1-3/8 in input shafts with a 0.98 in pilot bearing inner diameter. If maintaining the original clutch pressure plate, users must align the index marks before installing it onto dowels which should have two for diesel and three for gasoline configurations. Use the clutch alignment tool to properly set up the clutch disc pressure plate combination before securing the bolts using a star pattern and producing 45 Nm torque for the 5.4L and 6.8L engines yet employing 28 Nm torque for the 6.4L engine. Replace the transmission and carry out a normal system test after the removal of the clutch alignment tool.