Clutch Kit

This procedure covers removal and replacement of the clutch disc, pressure plate, pilot bearing, and throwout bearing on a 1972 Ford F-100 with 302ci V8 and manual transmission.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM specification for 302ci V8 with 10.5" or 11" clutch
• Pressure plate × 1 — Use OEM specification matching clutch disc diameter
• Throwout bearing (release bearing) × 1 — Use OEM specification
• Pilot bearing × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification for transmission model
• High-temperature clutch grease × 1 — Use specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove both rear wheels if needed for access (depending on frame clearance for transmission removal)
5. Inspect clutch hydraulic lines (if equipped) or clutch linkage for damage before beginning work

Procedure

1. 1

   Disconnect driveshaft
   Mark the relationship between driveshaft yoke and pinion flange for reassembly alignment. Remove the 4 U-joint strap bolts at the rear differential. Lower the driveshaft and slide it rearward out of the transmission tailshaft. Place a drain pan underneath as some fluid may drain. Stuff a rag into the tailshaft opening to prevent fluid loss.
2. 2

   Disconnect clutch linkage
   Disconnect the clutch release rod from the clutch fork at the bellhousing. Remove the retaining clip and clevis pin connecting the pushrod to the clutch fork. Note the adjustment settings before disconnection. Note the adjustment settings before disconnection.
3. 3

   Remove transmission crossmember
   Position the transmission jack securely under the transmission pan with a wooden block to distribute load. Apply slight upward pressure to support the transmission weight. Remove the 2 bolts securing the transmission mount to the crossmember. Remove the 4 bolts securing the crossmember to the frame rails and remove the crossmember.
4. 4

   Disconnect electrical connections and shifter
   Disconnect the backup light switch wire connector on the transmission. If equipped with 4-speed, remove the shifter handle from inside the cab by removing the shift ball and boot, then unbolting the shifter lever. For 3-speed column shift, disconnect the shift rods at the transmission.
5. 5

   Disconnect speedometer cable
   Locate the speedometer cable connection at the transmission tailshaft (side varies by transmission model — verify on your unit). Remove the cable retaining clip or bolt and carefully pull the cable straight out from the transmission housing. Do not bend the cable core excessively. Verified detail (On 1972 F-100 manual transmissions, the speedometer cable typically connects on the passenger (right) side of the transmission tailshaft housing, not the driver side.): Locate the speedometer cable connection at the passenger side of the transmission tailshaft.
6. 6

   Remove bellhousing to engine bolts
   Remove the lower bellhousing dust cover if equipped. Remove the bellhousing to engine block mounting bolts (typically 5-6 on this application). The upper bolts are accessed from above through the engine compartment. The lower bolts are accessed from underneath. Support the bellhousing as you remove the last bolt.
7. 7

   Remove transmission and bellhousing assembly
   Verify the transmission is securely supported on the transmission jack. Carefully slide the transmission and bellhousing rearward, keeping it level. The input shaft must clear the clutch disc and pilot bearing without binding. Once the input shaft clears the bellhousing, lower the transmission jack and roll the assembly out from under the vehicle. The transmission and bellhousing typically separate once removed, or may be separated on the bench.
8. 8

   Inspect flywheel and mark pressure plate
   With the clutch assembly now exposed, inspect the flywheel friction surface for heat checking, scoring, or warpage. Minor surface imperfections can be resurfaced; severe damage requires flywheel replacement. If reusing the pressure plate, use a center punch to mark the relationship between the pressure plate and flywheel at one location for balanced reassembly.
9. 9

   Remove pressure plate assembly
   Loosen the 6 pressure plate to flywheel bolts gradually in a crisscross pattern, approximately 1-2 turns at a time, to prevent warping the pressure plate. Once all bolts are loose, remove them completely. Support the pressure plate and clutch disc as you remove the last bolt. Remove the pressure plate and clutch disc together.
10. 10

    Remove pilot bearing
    Inspect the pilot bearing in the center of the crankshaft for roughness, noise, or wear. Remove the old pilot bearing using a pilot bearing puller or slide hammer with internal puller attachment. If using the old-school method, pack the cavity behind the bearing with grease and use a close-fitting shaft to hydraulically press the bearing out, though the puller method is preferred.
11. 11

    Remove throwout bearing
    Remove the throwout bearing (release bearing) from the clutch fork and transmission input shaft bearing retainer. Inspect the fork for cracks or excessive wear. Check the bearing retainer surface for wear grooves. The throwout bearing should be replaced with every clutch replacement.
12. 12

    Clean and inspect components
    Clean the flywheel surface with brake cleaner and wipe dry. Inspect for cracks, heat checking, or warpage. Check flywheel runout if a dial indicator is available; maximum runout is typically 0.010 inches. Clean the transmission input shaft splines with brake cleaner and wire brush. Inspect the input shaft seal for leakage; replace if necessary.
13. 13

    Install new pilot bearing
    Lightly coat the outer diameter of the new pilot bearing with high-temperature grease. Drive the pilot bearing into the crankshaft bore using a bearing driver or socket of appropriate diameter until it seats fully and squarely. The bearing should be flush with or slightly recessed from the crankshaft bore surface. Apply a small amount of high-temperature grease to the bearing interior.
14. 14

    Install new throwout bearing
    Apply a thin coat of high-temperature grease to the transmission input shaft bearing retainer where the throwout bearing slides. Install the new throwout bearing onto the clutch fork, ensuring it engages properly with the fork fingers. Verify the bearing slides freely on the bearing retainer without binding.
15. 15

    Install clutch disc and pressure plate
    Insert the clutch alignment tool through the new clutch disc and into the pilot bearing to center the disc. Install the clutch disc in the correct orientation — most discs are marked 'flywheel side' or 'transmission side'. Typically the protruding hub faces the transmission, but always follow the stamping on the disc to avoid interference with the flywheel bolts. Position the new pressure plate over the clutch disc, aligning the dowel pins (if equipped) or the previously made alignment marks if reusing the original pressure plate. Thread in the 6 pressure plate bolts by hand. Tighten the bolts gradually in a crisscross pattern in 2-3 stages to pull the pressure plate down evenly. Leave the clutch alignment tool in place until all bolts are 70.0 lb-ft (95.0 Nm). Remove the alignment tool once complete. Verified detail (Pressure plate to flywheel bolts on a Ford small-block are typically torqued higher, around 25-35 ft-lbs. 15-20 ft-lbs is likely too low. Verify against factory spec.): 25-35 ft-lbs
16. 16

    Reinstall transmission and bellhousing
    With assistance or using the transmission jack, position the transmission and bellhousing assembly under the vehicle. Raise the assembly into position, carefully aligning the transmission input shaft with the clutch disc splines and pilot bearing. The input shaft must slide through the clutch disc without forcing. If resistance is encountered, lower slightly and rotate the transmission output shaft by hand to align the splines. Once the bellhousing mates flush with the engine block, install the 4 bellhousing to engine bolts and tighten securely.
17. 17

    Reinstall crossmember and transmission mount
    Raise the transmission jack slightly to align the transmission mount with the crossmember position. Install the crossmember to frame rail bolts and secure. Install the transmission mount to crossmember bolts and tighten. Lower the transmission jack to allow the mount to support the transmission weight, then remove the jack.

Reassembly

1. Reconnect the speedometer cable to the transmission tailshaft and secure with retaining clip or bolt
2. Reconnect backup light switch electrical connector
3. Reconnect shifter mechanism (install shifter assembly for floor shift, or reconnect shift rods for column shift)
4. Reinstall driveshaft, aligning the marks made during disassembly, and torque U-joint strap bolts
5. Reconnect clutch linkage to the clutch fork and adjust clutch pedal free play per factory specifications
6. Reconnect negative battery cable
7. Lower vehicle from jack stands

Verification

• Start engine and verify it starts in neutral only (backup light switch functioning)
• With engine running and clutch pedal depressed, shift through all gears to verify smooth engagement without grinding
• Test clutch engagement point and pedal feel; adjust linkage if necessary to achieve proper 1-inch free play at pedal
• Road test vehicle through all gears under light and moderate load to verify smooth clutch operation without slipping or chattering
• Verify no fluid leaks from transmission input shaft seal
• Check for abnormal noises from throwout bearing when clutch pedal is depressed

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