OEM 2009 Ford F-250 Super Duty Clutch Disc

2009 Ford F-250 Super Duty Clutch Disc Parts Q&A

• Q: How to remove and replace the clutch disc and pressure plate on 5.4L, 6.8L, and 6.4L engines on 2009 Ford F-250 Super Duty?

  A: A technician should begin clutch disc and pressure plate replacement on 5.4L, 6.8L, 6.4L engines by disconnecting the transmission assembly. Index the clutch pressure plate and measure the flywheel surface when you plan to reinstall them. The next step requires removal of the clutch pressure plate bolts after which you can take out the clutch pressure plate and clutch disc. The transmission input shaft pilot bearing must be inspected for all defects including misalignment and looseness as well as scoring and discoloration and wear and broken rollers and damaged seals. Substitute this bearing when any damage exists. To check the clutch disc friction surface use emery cloth to remove small flaws then check if the disc shows signs of oil absorption and inspect rivets for damage and springs for wear and splines for wear patterns which need replacement. Use a suitable solution to clean the clutch pressure plate friction surface while looking for lever wear and checking the friction surface for scoring, burning, distortion or warping replacing the parts if any damage emerges. Point out small damages on the flywheel rub surface for further evaluation before you try to remedy them with emery cloth or sandpaper of 400-grit grade. Inspect the ring gear for damage to its teeth. The transmission input shaft pilot bearing requires grease application before installing. Administrators can reset the wear indicator on original clutch pressure plates through a process of finger pressure followed by counterclockwise calibration of tension springs before releasing the pressure. The pilot bearing of the clutch disc requires a 1-1/4 in input shaft for 5.4L/6.8L engines and a 1-3/8 in input shaft with a 0.98 in pilot bearing inner diameter for 6.4L engines before aligning it with a clutch alignment tool. The original clutch pressure plate should be installed with the index marks aligned and two dowels used for diesel engines while gasoline engines require three dowels. The clutch disc and pressure plate alignment requires the clutch alignment tool before installing pressure plate bolts with star pattern torque at 45 Nm (33 lb-ft) for 5.4L and 6.8L engines and 28 Nm (21 lb-ft) for the 6.4L engine. Reinstall the transmission while testing the system for normal operation after removing the clutch alignment tool.