Clutches Ford Bronco II I

DESCRIPTION

The hydraulic clutch control consists of the hydraulic master cylinder, slave cylinder, reservoir, and connecting tubing. The clutch disc and pressure plate are single disc type. The clutch release bearing or bearing arm is activated by hydraulic pressure. The pilot bearing is mounted inside the bellhousing and requires no lubrication unless the clutch assembly is serviced. The clutch linkage or pedal position requires no adjustments.

CLUTCH/STARTER INTERLOCK SWITCH

1. Disconnect wiring connector at switch by flexing retaining tab. Test electrical continuity of switch with ohmmeter. Switch should be open (infinity) when pedal is up and clutch is engaged. Switch should be closed (zero ohms) when clutch pedal is pressed to floor.
2. If switch does not operate properly, check position of self-adjusting clip. Adjust switch by removing both halves of clip and position clip closer to switch body. Reset switch by depressing clutch pedal to floor. If switch still does not function properly, replace switch.

Scheme 1

HYDRAULIC SYSTEM BLEEDING

1. Clean area around reservoir cap of any dirt or grease. Fill reservoir to top with DOT 3 brake fluid. Run hose from bleeder screw to container to avoid having brake fluid get into bellhousing. Loosen bleed screw and keep fluid level in reservoir to step.
2. Fluid and bubbles will flow from tube attached to slave cylinder bleed screw. When stream of fluid is free of air bubbles, close bleed screw. Ensure fluid in reservoir is level with step. Put diaphragm and cap on reservoir.
3. Place light load on clutch pedal and open bleed screw. Maintain pressure until pedal reaches floor. Close bleed screw while keeping pedal fully depressed. DO NOT allow pedal to return before bleed screw is fully tightened. Top up reservoir to step.
4. On all vehicles, test system by starting vehicle, depressing clutch and placing shift lever into Reverse. No grinding should be heard or felt with clutch pedal within 1/2" (13 mm) of floor. If noise is heard, check for air in system. Repeat bleeding procedure if necessary.

Removal

1. Place transmission in Neutral. Remove boot retainer screws. Remove bolts holding gearshift lever assembly. Pull gearshift lever assembly out of transfer case adapter (extension housing). Cover opening to keep dirt out.
2. Disconnect negative battery cable. Raise and support vehicle. Mark driveshaft and rear axle flange for reassembly reference. Disconnect driveshaft at rear axle drive flange.
3. Pull driveshaft rearward and disconnect from transmission. Install plug in transfer case adapter (extension housing). Disconnect hydraulic line from master cylinder (clutch housing). Plug opening to avoid leaks.
4. Remove speedometer cable from transfer case adapter (extension housing). Disconnect wiring from starter motor and transmission switch(es). Place jack under engine and wood block under oil pan. On 4WD vehicles, remove transfer case.
5. Remove starter motor. Place jack under transmission. Remove bolts, lock washers, and flat washers attaching transmission to engine plate. Remove bolts holding transmission mount and damper to crossmember.
6. Remove crossmember. Lower engine jack. Remove clutch housing from locating dowels. Slide transmission rearward until input shaft spline clears clutch disc. Remove transmission from vehicle.

Installation

To install transmission, reverse removal procedure. Be sure to align splines on input shaft with splines in clutch disc.

Remove transmission. Mark pressure plate and flywheel for reassembly reference. Loosen bolts holding pressure plate to flywheel evenly until springs are expanded. Remove pressure plate and clutch disc from flywheel.

1. Clean pressure plate and flywheel surface with commercial alcohol base solvent. Place clutch disc on flywheel. Align disc center with pilot bearing using old input shaft or clutch pilot shaft. Place pressure plate on flywheel and align marks made during disassembly.
2. Tighten bolts evenly in clockwise rotation. Tighten every other bolt for first 3 bolts, then skip to fourth bolt, then every other bolt until all 6 bolts are tightened. Remove clutch pilot shaft. Reverse removal procedure to complete installation.

Remove transmission, bellhousing, and clutch slave cylinder. Bend back 4 plastic retainers on bearing carrier. Remove bearing from carrier.

Using lithium-based grease, fill annular groove of release bearing. Coat inside diameter of bearing with thin film of grease. Push release bearing into carrier. Make sure bearing is aligned with 4 retainers of carrier. Install slave cylinder in housing.

Remove transmission, pressure plate, and clutch disc. Use Slide Hammer (T59L-100-B) and Puller (T58L-101-A) to remove pilot bearing.

Lightly coat crankshaft bore with lithium-based grease. Using Clutch Aligner (T71P-7137-H) and Bearing Driver (T74P-7137-A), install pilot bearing with seal toward transmission. Install clutch disc, pressure plate, and transmission. Use care when installing transmission so that input shaft does not damage pilot bearing.

Note. Use Bearing Driver (T74P-7137-C) on 2.3L engine.

CLUTCH HYDRAULIC SYSTEM

Note. On all models, disconnect master cylinder push rod if slave cylinder is to be disconnected from release lever or bearing. Permanent damage to slave cylinder will occur if master cylinder is activated with slave cylinder disconnected.

1. Note position of clutch pedal push rod. Disconnect master cylinder push rod from clutch pedal by prying retainer bushing and push rod off shaft. Remove reservoir from cowl access cover or from electrical box cover.
2. Remove bellhousing clip retaining tube to slave cylinder. On all vehicles, remove master cylinder from firewall. 3 Remove tube, fitting (if used), master cylinder, and reservoir as an assembly. Plug lines. Remove transmission and bell-housing. Note position of slave cylinder and remove from bellhousing.

Scheme 2

1. Install slave cylinder. Ensure that cylinder is properly engaged in notches of clutch housing. Install transmission and bellhousing. Insert master cylinder push rod through opening in firewall.
2. Ensure push rod is located on correct side of clutch pedal. Attach master cylinder to firewall. Insert tube and fitting in clutch slave cylinder. Install fluid reservoir on access cover.
3. Install bushing and push rod on clutch pedal. Bleed hydraulic system. Depress clutch pedal at least 10 times to check for proper release and smooth operation.

Scheme 3

Remove retainer clip and disconnect clutch/starter interlock switch rod from clutch pedal. Using screwdriver between master cylinder push rod and clutch pedal, pry out rod and bushing from clutch pedal pin. Remove retainer clip, clutch pedal, and shaft assembly from support bracket.

To install, reverse removal procedure. Check bushing and shaft for wear or damage. Replace parts as necessary. Lubricate bushings with light film of SAE 30 oil. Check and adjust interlock switch if necessary.

CLUTCH BELLHOUSING ALIGNMENT

Note. Whenever bellhousing is removed from engine or replaced, alignment must be checked to prevent excessive transmission wear, drive train vibration, clutch pilot and release bearing noises, or transmission jumping out of gear.

Scheme 4

Scheme 5

Scheme 6

1. With transmission and bellhousing removed, check for nicks and burrs and remove paint and other foreign material from bellhousing faces and bore surfaces, rear of engine block, and rear engine plate. Make sure locating dowels are tight and in good condition.
2. Mount bellhousing and rear engine plate on engine block. Tighten bolts holding bellhousing to block to specification. Install Post Assembly (T75L-6392-A) into clutch disc with dial indicator base post attached. (Scheme 4)
3. Tighten nut on end of post until clamp expands and locks into clutch disc hub. Post assembly movement must not be evident as erratic readings would result. Mount dial indicator on post assembly using universal bracket and short Support Bar (T75L-4201-B).
4. Position dial indicator so tip rests against rear face of bellhousing at right angle. (Scheme 5) Push crankshaft to rear to eliminate end play. Zero dial indicator. While pushing crankshaft toward rear, rotate crankshaft one complete revolution.
5. Check that dial indicator has returned to zero when starting point is reached. If reading is not zero, end play or loose post have affected reading. Note maximum and minimum readings of dial indicator during one revolution to determine face runout. Repeat measurement for accuracy and verification.
6. Attach lever adapter to dial indicator. Place rubber band as shown to preload dial indicator and to provide constant light pressure of lever tip against bellhousing bore inner circumference. DO NOT make rubber band too tight. (Scheme 6) Zero dial indicator.
7. Rotate crankshaft one complete revolution. Record maximum variation of indicator. Repeat procedure again to verify reading. If face runout exceeds.010" (.25 mm) and/or bore runout exceeds.015" (.38 mm), bellhousing alignment must be corrected. Shims may be used to correct face runout. (Scheme 7)
8. Shim required must be half of largest negative dial indicator reading. Shim should be installed between bell-housing and engine block at largest negative reading. Repeat measurements. If both bore and face runouts are out of limits, shim bellhousing until face runout is correct.
9. Check bore runout again. If bore runout is still excessive, shim bellhousing to limit of face runout. If bore runout is still excessive, bellhousing must be replaced.

Scheme 7

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS