Maverick and Comet Repair
Clutch and Transmission
CLUTCH
REMOVAL AND INSTALLATION
With the car raised on a lift, disconnect the driveshaft at its rear
flange. Slide the drive-shaft from the transmission output shaft.
Plug the opening in the extension housing. Disconnect the
speedometer cable from the extension housing and the transmission
controlled spark cable, if so equipped Disconnect the gearshift rods
from the transmission. Withdraw the bolts securing the transmission
to the flywheel housing and move the transmission to the rear until
the input shaft is clear of the flywheel, then remove it from the
car. Disconnect and remove the retaining spring from the clutch
release lever. Remove the starter motor cable and remove the starter
motor from the flywheel housing. Remove the bolts securing the
engine rear plate to the front lower part of the flywheel housing.
Remove the bolts attaching the housing to the cylinder block, then
move the housing back just enough to clear the pressure plate and
move it to the right to free the pivot from the clutch equalizer
bar. Be careful that the linkage and assist spring are not
disturbed. Gradually and evenly loosen the six pressure plate cover
bolts to release the spring tension and avoid distortion of the
cover.
NOTE: If the same pressure plate and cover are to be reinstalled, the cover and flywheel should be marked so that the pressure plate can be installed in its original position.
Remove the bolts, pressure plate and clutch
disc from the flywheel.
Install the clutch release lever, if it
was removed, and position the clutch disc and pressure plate
assembly on the flywheel. Partially install the cover attaching
bolts in order to hold the components in place, but do not tighten
the bolts yet.
NOTE: When handling the clutch components,
especially the clutch disc face, avoid allowing grease or dirt to
contact the parts.
Use an old transmission input shaft or a clutch aligning tool (see accompanying illustration) to line up the clutch disc, and alternately tighten the bolts gradually until they are all tight. Before removing the input shaft or aligning tool, tighten the cover bolts to a torque of 12-20 ft. lbs. A light film of grease should be applied to the outside diameter of the transmission front bearing retainer and also to both sides of the release lever fork where the fork contacts the release bearing bore spring clips. Use a light film of grease on the release bearing surface where contact is made with the pressure plate release fingers and fill the grease groove of the release bearing hub with grease. Lithium-base grease is specified for all clutch lubrication applications. All excess grease should be cleaned from the inside bore of the bearing hub, as excess grease could find its way to the clutch disc and cause slippage.
Place the release bearing and the hub on the release lever. Examine the flywheel housing and cylinder block mounting surfaces for cleanliness and position the felt washer on the pivot in the flywheel housing. Being careful not to disturb the clutch linkage, slip the pivot into the clutch equalizer shaft and position the flywheel housing on the dowels in the cylinder block. Install the attaching bolts and alternately tighten to 23-33 ft. lbs. on 1970-72 six-cylinder models; 40-50 ft. lbs. on 1971-72 V8 models; and 38-55 ft. lbs. on all 1973-77 models. Install the starter motor and replace the cable. Having ensured that the joining surfaces of the transmission and flywheel housing are clean and smooth, insert two guide pins in the flywheel housing lower mounting bolt holes. Push the transmission forward on the guide pins until it is tight against the flywheel housing. Install the two upper mounting bolts, remove the guide pins from the lower mounting holes and install the lower bolts. The bolts should be tightened to 37-42 ft. lbs.
With the rear of the engine raised, install the crossmember and attaching bolts, then lower the engine. Install and tighten the extension housing-to-engine rear support bolts. Remove the jack from the transmission and connect the cable for the parking brake. Connect the gearshift rods to the transmission and adjust the shift linkage if necessary. Connect the release lever retaining spring. Remove the sealing tool from the transmission output shaft and install the driveshaft. Check the free-play of the clutch pedal as outlined in the following section.