Warning: Clutch wear dust may contain asbestos, which is very dangerous to health. Do not blow off dust with compressed air or inhale air containing asbestos. Wear a respirator. DO NOT clean dust with gasoline (or gasoline-based solvents). Use brake fluid or methylated spirits. After cleaning components, place used rags in a sealed, labeled container.
Removal
1. There are two options for accessing the clutch pedal. First: remove the power unit (chapter 2B) and separate the transmission from the engine on the workbench. Second: remove the transmission without removing the engine from the car (Chapter 7A or 7B). In the second method, keep in mind that to remove the transmission, it must be moved to the left in the engine compartment (see Fig. 7.1).
2. After separating the transmission from the engine, check the clutch cover and flywheel for alignment marks. If there are no marks, apply them with a drop of paint or a scriber (see Fig. 7.2). You will need these marks if you reinstall the cover. This will also help maintain the balance of the unit. The new cover can be installed in any position that the pins allow.
3. Remove the six clutch cover mounting bolts. Loosen the bolts in a crisscross pattern, one turn at a time (see Fig. 7.3). If necessary, the flywheel can be locked with a screwdriver. To do this, insert it into the teeth and rest it on the cylinder block.
4. Remove the clutch cover from the mounting pins. Be prepared to catch the friction disc that falls out when you remove the cover (see Fig. 7.4). Note which side the disc is installed.
Inspection
5. Most often, clutch failure is associated with wear of the friction disc. However, it is still necessary to inspect all clutch components, especially if the car has a high mileage. Regardless of the fact that the components look serviceable, it is recommended to replace them as a set (friction disc, pressure plate and release bearing). Replacing only the worn friction disc does not always give a result, especially if the old disc was sticking, causing the pressure plate to overheat.
6. Inspect the friction disc for lining wear, loose rivets, cracks, disc warping, spline wear, and breakage of the damping springs (if any). The lining surfaces may be shiny, but this is acceptable as long as they look clean. The distance from the lining surfaces to the rivet heads should be at least 1 mm.
7. If the lining surfaces are contaminated with oil, which appears as stains or a solid change in colour to shiny black, the disc must be replaced. Identify and eliminate sources of contamination before installing new clutch components. Typical causes of contamination are leaks from the rear crankshaft oil seal (consult your dealer for replacement) or the transmission input shaft oil seal (see Chapter 2, Replacement). The disc must also be replaced if the linings are worn down to the rivet heads.
8. Inspect the machined surfaces of the flywheel and pressure plate. If there are grooves or deep burrs, replace the corresponding part. The pressure plate must also be replaced if there are cracks on it, if the diaphragm spring is damaged or its force changes.
9. While the gearbox is removed, it is recommended to check the condition of the release bearing (paragraph 7). It almost always makes sense to replace it.
Installation
10. When installing new clutch components, it is necessary to remove the protective anti-corrosion coating (if any) from the friction material of the disc and the contact surfaces of the pressure plate and flywheel. It is necessary to prevent oil from getting on the friction disc linings, as well as on the surfaces of the pressure plate and flywheel. Before starting to install the units, it is recommended to wipe the surfaces of the pressure plate and flywheel with a rag and perform the work with clean hands.
11. Ford recommends a special tool for centering the disc. If you do not have one, follow these instructions.
12. Press the disc onto the flywheel so that the side of the hub with the large protrusion faces away from the flywheel. The disc is usually marked "Flywheel side" and should face the flywheel (see Fig. 7.12).
13. Install the clutch cover onto the pins, aligning the marks (if any) on the clutch cover and flywheel. Insert the mounting bolts and tighten them by hand until the friction disc is secured but still able to slide.
14. After this, you need to center the friction disc so that when connecting the engine to the transmission, the splines of the gearbox input shaft enter the splines of the friction disc hub.
15. Centering can be accomplished as follows. Insert a round rod or a long screwdriver into the hole in the center of the friction disc so that the end of the rod rests against the center of the crankshaft end face inside the tailstock bearing. If possible, use a blunt tool, and if using a screwdriver, wrap its tip with tape to avoid damaging the bearing surfaces. Center the friction disc by moving the rod from side to side and up and down. After removing the rod, visually inspect the centering of the friction disc hub relative to the circle formed by the diaphragm spring petals.
16. Another method of centering using a special device is more reliable and eliminates the need for visual control (see Fig. 7.16.).
17. Tighten the cover mounting bolts to the specified torque in a crisscross pattern.
18. Apply high-melting grease to the input shaft splines and the release bearing guide sleeve.
19. Install the transmission.
(The article was taken in its entirety from the specified website Fordbook.ru)