Flywheel

This procedure covers removal and replacement of the flywheel (manual transmission) or flexplate (automatic transmission) on a 1972 Ford F-100 with 302ci V8, requiring transmission removal and rear engine access.

Warnings

Tools required

Parts

• Flywheel or flexplate (manual or automatic as applicable) × 1 — Use OEM specification
• Pilot bearing (manual transmission only) × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Clutch kit (manual transmission, if replacing while apart) × 1 — Use OEM specification
• Transmission pan gasket (automatic only) × 1 — Use OEM specification

Fluids

• Type F ATF (automatic transmission) — 11 qt
• 80W-90 GL-5 (rear differential) — 3.5 qt

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 driveshaft: mark alignment between driveshaft yoke and rear axle pinion yoke, remove 4 U-joint strap bolts, slide driveshaft rearward and remove from transmission
5. Drain transmission fluid into appropriate container (automatic transmission only)
6. Drain rear differential if servicing (optional maintenance while access is available)
7. Disconnect speedometer cable from transmission
8. Disconnect shift linkage (automatic) or clutch linkage and remove bellhousing inspection cover (manual)
9. Disconnect transmission cooler lines if equipped with automatic transmission
10. Support engine from above using engine support bar or chain hoist with slight upward tension

Procedure

1. 1

   Support and disconnect transmission mounts
   Position transmission jack under transmission pan with wood block to distribute load. Remove transmission crossmember bolts (2 bolts each side at frame rails). Remove crossmember by lowering transmission jack slightly and sliding crossmember out. Disconnect any electrical connectors including neutral safety switch (automatic) or reverse light switch (manual).
2. 2

   Remove transmission-to-bellhousing bolts
   For automatic transmission, remove the 6 bolts securing the transmission bellhousing to the engine block. For manual transmission, remove the 4 bolts securing bellhousing to engine block. Support transmission weight on jack while removing final bolts. Note: top bolts may require extension and universal joint for access.
3. 3

   Separate and lower transmission
   Carefully slide transmission rearward on jack, keeping it level. Manual transmission: ensure input shaft clears clutch disc and pilot bearing. Automatic transmission: ensure torque converter stays with transmission (may need to hold in place). Lower transmission completely and remove from under vehicle. Manual transmission: bellhousing may come with transmission or remain on engine depending on configuration.
4. 4

   Remove clutch assembly (manual transmission only)
   If equipped with manual transmission, mark pressure plate orientation to flywheel with punch or paint. Remove the 6 pressure plate bolts gradually in cross pattern (loosen each 2-3 turns at a time to prevent warping). Remove pressure plate and clutch disc. Inspect clutch components; replace if worn since access is already available.
5. 5

   Mark flywheel/flexplate position
   Mark flywheel or flexplate position relative to crankshaft flange using punch or paint marker. This maintains engine balance during reinstallation. Note position of any offset dowel pins if present.
6. 6

   Lock crankshaft rotation
   Install flywheel holding tool to prevent crankshaft rotation, or wedge large screwdriver or pry bar between flywheel teeth and bellhousing/block. Ensure tool engages securely to prevent damage during bolt removal.
7. 7

   Remove flywheel/flexplate bolts
   Remove the 8 flywheel bolts (manual) or 8 flexplate bolts (automatic) in cross pattern. Note: these bolts are high-strength; inspect threads and replace if damaged. They are standard reusable bolts (not torque-to-yield) on this application. Remove flywheel holder tool.
8. 8

   Remove flywheel or flexplate
   Pull flywheel or flexplate straight off crankshaft flange. Flexplate may require slight wiggling to clear torque converter mounting studs. For manual transmission, remove pilot bearing from center of crankshaft using slide hammer with pilot bearing puller attachment or pack with grease and hydraulically remove with appropriately sized rod.
9. 9

   Inspect and clean mounting surfaces
   Inspect crankshaft flange for cracks, wear, or damage. Clean crankshaft flange and flywheel/flexplate bolt holes thoroughly with wire brush and solvent. Inspect flywheel for cracks, heat checking, or excessive wear on friction surface. Manual: check for ring gear damage. Automatic: check flexplate for cracks especially around torque converter bolt holes. Replace flywheel/flexplate if damaged beyond resurfacing limits.
10. 10

    Install pilot bearing (manual transmission only)
    For manual transmission, install new pilot bearing into center of crankshaft. Drive bearing in squarely using appropriately sized bearing driver or socket until flush with crankshaft bore. Ensure bearing is seated fully and oriented correctly (sealed side facing out).
11. 11

    Install flywheel or flexplate
    Align flywheel or flexplate to crankshaft flange matching alignment marks made during removal. Ensure any dowel pins engage correctly. For automatic transmission, align flexplate so torque converter bolt holes are accessible. Start all 8 bolts by hand to ensure proper thread engagement.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
12. 12

    Torque flywheel/flexplate bolts
    Install flywheel holder tool to lock crankshaft. Tighten flywheel/flexplate-to-crankshaft bolts to approximately 75-85 lb-ft in star/cross pattern (verify exact factory specification for the 302). Apply medium-strength threadlocker to bolt threads if specified by service manual. Make at least two complete passes: first to 50% torque, then to final torque specification. Remove flywheel holder tool. Verified detail (Ford 302 flywheel bolts are typically torqued to 75-85 lb-ft, not 70 lb-ft. Flexplate torque of 63 lb-ft may be low; typically 75-85 lb-ft for this application. These values should be verified against factory specifications.): Tighten flywheel bolts (manual) to 102-115 Nm (75-85 lb-ft) in star/cross pattern, or flexplate bolts (automatic) to 102-115 Nm (75-85 lb-ft) in star/cross pattern.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
13. 13

    Install clutch assembly (manual transmission only)
    For manual transmission, install clutch disc and pressure plate. Center clutch disc using alignment tool (old input shaft or dedicated tool) to align with pilot bearing. Install pressure plate aligned with marks made during removal. Start all 6 pressure plate bolts by hand, then tighten gradually in cross pattern to specification (typically 23-28 lb-ft - verify exact specification). Remove clutch alignment tool.
14. 14

    Inspect and replace rear main seal
    Since transmission is removed, inspect rear main seal for leakage. If seal shows any signs of leakage or vehicle has high mileage, replace seal now. For 2-piece seal: carefully remove the lower seal half from the main cap and gently roll the upper half out of the block (a small pin or seal-removal tool can help push it around the journal), then install the new seal per factory procedure without damaging the crankshaft surface. The 1972 302 uses a 2-piece rear main seal: carefully remove the upper and lower seal halves and install the new seal per factory procedure, taking care not to damage the crankshaft sealing surface.
15. 15

    Reinstall transmission
    Raise transmission into position using transmission jack. Manual: ensure input shaft aligns with clutch disc and pilot bearing (rotate output shaft slightly if needed). Automatic: ensure torque converter is fully seated in pump (should click into place and sit approximately 1/2" recessed from bellhousing face). Slide transmission forward carefully, ensuring alignment dowels engage. Install transmission-to-bellhousing bolts and torque to specification (typically 40-50 lb-ft for this application). Install crossmember and torque mounting bolts. Reconnect all linkages, electrical connectors, speedometer cable, and cooler lines (automatic). Reinstall driveshaft aligned with marks made during removal. Remove engine support.

Reassembly

1. Refill automatic transmission with 11 quarts Type F ATF, checking level with engine running in Park after warmup
2. Refill rear differential with 3.5 quarts 80W-90 GL-5 if drained during service
3. Adjust clutch free play if equipped with manual transmission per factory specification
4. Reconnect negative battery cable
5. Road test vehicle through all gears and verify smooth operation without vibration, noise, or clutch slippage
6. Recheck all fluid levels after test drive

Verification

• Engine should crank and start normally without unusual noises from flywheel/flexplate area
• Manual transmission: clutch should engage smoothly without chatter or slippage under load
• Automatic transmission: verify smooth shifts through all gears without slipping or harsh engagement
• No vibration should be present at any engine speed - vibration indicates flywheel imbalance or improper driveshaft alignment
• Check for fluid leaks around transmission and rear main seal area after test drive
• Verify proper clutch pedal free play on manual transmission (typically 3/4" to 1" at pedal)

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