Clutches Ford Tempo I

DESCRIPTION

Clutch is a single dry disc design with a Belleville spring type pressure plate. All models use a self-adjusting cable operated clutch system.

SELF-ADJUSTING CLUTCH

On cable controlled models, clutch cable is adjusted automatically by a self-adjusting mechanism attached to clutch pedal.

Note. Before changing clutch, you must first remove sub-frame and transmission.

Scheme 1

1. Disconnect negative battery cable. Wedge a wood block (approximately 7") between clutch pedal and floor to hold clutch pedal up beyond its normal position. Disconnect clutch cable at release fork.
2. Remove clutch cable casing from rib on transaxle case. Remove 2 upper transaxle-to-engine bolts. Remove top bolt that secures air management valve bracket to transaxle (if necessary). Raise and support vehicle.
3. Remove nut and bolt securing lower control arm ball joint to steering knuckle assembly. Discard nut and bolt. Repeat procedure on other side. Using Half-Shaft Remover (D83P-4026-A) or equivalent, pry lower control arm away from knuckle. Repeat on other side. (Scheme 1): Exploded View of Ford FWD Clutch Assembly CAUTION: Use care when using pry bar to remove CV joint. Damage to oil seal may result.
4. Using large pry bar, pry left side inboard CV joint assembly from transaxle. Install Transaxle Plugs (T81P-1177-B) or equivalent to prevent transaxle from draining.
5. Swing steering knuckle and half-shaft outward from transaxle. Secure half-shaft (using wire) in a near level position to prevent damage. Repeat on other side.
6. Disconnect backup light switch on top of transaxle. Remove 3 starter bolts and remove starter. Remove shift mechanism-to-shift shaft attaching nut and bolt. Disconnect mechanism from shift shaft.
7. Remove shift mechanism stabilizer bar from transaxle and remove control selector indicator switch arm from shaft. Remove 2 stiffener braces from front of bellhousing and remove speedometer cable.
8. Secure transaxle jack under transaxle and remove 2 bolts attaching rear support mount to floorpan brace. Loosen nut on bottom of front support mount. Remove 3 bolts securing front mount to transaxle.
9. Lower transaxle until it clears rear mount. Support engine block with a screw jack stand and wood block under oil pan. Remove 4 engine-to-transaxle bolts and lower transaxle from vehicle.
10. If same pressure plate cover is to be installed, index mark pressure plate cover to flywheel. Loosen 6 pressure plate cover attaching bolts evenly to avoid distorting cover. Remove pressure plate and clutch disc from flywheel.
11. Remove pin attaching release bearing to clutch release fork. Remove set bolt attaching clutch release fork to clutch release shaft on transaxle. Slide clutch release shaft assembly out from transaxle.

Installation

1. Clutch disc must be installed with flatter side toward flywheel as marked. Position clutch disc and align dowel pins of pressure plate onto flywheel. Start pressure plate cover bolts but DO NOT tighten to flywheel. Install Clutch Plate Aligner (T81P-7550-A) or equivalent into crankshaft pilot bearing.
2. With clutch aligned, alternately tighten pressure plate cover bolts until they are fully seated. Torque cover bolts to specifications and remove clutch aligner.
3. Before installation of transaxle, lubricate: outside diameter of transaxle front bearing retainer, inside of release bearing, clutch release fork fingers and contact surface of release shaft.
4. To complete installation of transaxle, reverse removal procedure. Use new nut and bolt when attaching lower control arm ball joint to steering knuckle.

Removal

1. Lift clutch pedal to its upward most position to disengage pawl and quadrant. Push quadrant forward and unhook cable from quadrant and allow it to slowly swing rearward.
2. Remove screw (from engine side) that holds cable assembly insulator to dash panel. Pull cable through dash panel and into engine compartment. Remove cable bracket screw from fender apron.
3. Raise vehicle on a hoist. Slide ball on end of cable through hole in clutch release fork and remove cable.

1. Insert clutch cable through bellhousing and attach ball on cable end to clutch release fork. Install clip retainer that holds cable assembly to bellhousing.
2. Route cable through engine compartment and lower vehicle. Attach cable bracket to fender and push cable assembly into hole in dash panel and secure insulator with a screw.
3. Install cable assembly by lifting clutch pedal to disengage pawl and quadrant. While pushing quadrant forward, hook end of cable over rear of quadrant. Push pedal several times to adjust clutch.

1. Disconnect negative battery cable. Remove steering wheel using Steering Wheel Puller (T67L-3600-A) or equivalent. Remove lower dash panel section to the left of steering column.
2. Remove shrouds from steering column. Disconnect brake light switch and master cylinder push rod from brake pedal. Rotate clutch quadrant forward and unhook clutch cable. Allow quadrant to slowly swing rearward.
3. Remove bolt holding brake pedal support bracket (lateral brace) to left side of vehicle. Disconnect all electrical connectors leading to steering column. Remove 4 nuts holding steering column to brake pedal support bracket and lower steering column to the floor.
4. Remove 4 booster nuts that hold brake pedal support bracket to dash panel. Remove bolt that holds bracket to underside of instrument panel. Remove bracket assembly from vehicle.
5. Remove clutch pedal shaft nut and clutch pedal. Slide self-adjusting mechanism out of brake pedal support bracket. Remove self-adjusting mechanism shaft bushings from both sides of brake pedal support bracket and replace if worn.

Self Adjusting Quadrant Assembly. Scheme 2

1. Lubricate self-adjusting mechanism shaft with motor oil. Install mechanism into brake pedal support bracket. Position quadrant in an upward position. Align flats on shaft with flats in clutch pedal assembly and install retaining nut.
2. Position brake pedal support bracket assembly beneath instrument panel aligning 4 holes with studs in dash panel. Install 4 nuts loosely. Install bolt through support bracket into instrument panel and tighten.
3. Tighten 4 booster nuts that hold brake pedal support bracket to dash panel. Connect brake light switch and master cylinder push rod to brake pedal. Attach clutch cable to quadrant. Position steering column onto 4 studs in support bracket and start 4 nuts.
4. Connect steering column electrical connectors and install steering column shrouds. Install brake pedal support (lateral brace). Tighten steering column attaching nuts. Install lower dash panel section.
5. Install steering wheel assembly and connect negative battery cable. Check steering column for proper operation. Depress clutch pedal several times to adjust cable.

Removal & Installation

Remove slave cylinder dust cover by removing self tapping screw. Unlatch slave cylinder from transmission housing bracket. Remove pressure line (if necessary) by removing roll pin. To install, reverse removal procedure. Use new "O" ring and roll pin when installing pressure line.

1. Remove slave cylinder. Remove 2 nuts attaching master cylinder reservoir to vacuum bracket. Disengage push rod from clutch pedal.
2. Turn master cylinder 45 degrees clockwise and gently pull master cylinder out. Remove pressure line (if necessary) by removing roll pin. To install, reverse removal procedure. Use new "O" ring and roll pin when installing pressure line.

Remove transmission, pressure plate and clutch disc. Pull bearing from crankshaft using Slide Hammer (T50T-100A, T59L-100B) and Puller Attachment (T58L-101-A).

Servicing Pilot Bearings. Scheme 3

1. Ensure that crankshaft pilot bore is clean and free from nicks or burrs. Lightly coat pilot bearing bore of crankshaft with Lubricant (C1AZ-19590-B).
2. Install pilot bearing (with seal end toward transmission) using Clutch Aligner (T71P-7137-H) and Pilot Bearing Installer (T71P- 7137-C). Carefully tap pilot bearing squarely into bore until flush with flywheel.

Note. Care must be taken when installing transmission, so that input shaft does not damage bearing.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS