2003 FORD MUSTANG clutch

2.
NOTE: If reusing the clutch pressure plate, align the plate using the marks made during
removal.
Using the special tool, align the clutch pressure plate and install it on the dowels.
zInstall the bolts in the sequence shown.
z Remove the special tool.
3. NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input
shaft must be cleaned and lubricated with grease.
Install the transmission. For additional information, refer to Section 308 - 03A (T5OD) or
Section 308 - 03B (TR3650). Klj . 2 ba
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REMOVAL AND INSTALLATION
Disc and Pressure Plate —
4.6L (4V) Engine
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the transmission. For additional information, refer to Section 308 - 03C .
3. Remove the starter. 1. Remove the terminal cap.
2. Remove the nuts.
3. Remove the wires and position them aside.
4. Remove the two bolts and the starter.
4. Remove the clutch cable clip, then pull the cable through the clutch housing.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Special Tool(s)
Clutch Aligner
308-
020 (T74P-7137- K)
Material Item Specification
Premium Long Life Grease
XG
-1-C ESA-
M1C75- B Klj . 1 ba
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5. Remove the two bolts and the inspection cover.
6. Remove the seven bolts and the clutch housing.
7.
CAUTION: Loosen the bolts evenly to prevent damage to the pressure plate.
NOTE: If the pressure plate is to be reused, index- mark the pressure plate to the flywheel.
Remove the six bolts and the pressure plate and disc. Klj . 2 ba
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Installation
1. NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol- based solvent
so surfaces are free from oil film. Do not use cleaners with a petroleum base.
NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input
shaft must be cleaned and lubricated with grease.
To install, reverse the removal procedure.
zUsing the special tool, align the clutch disc and pressure plate to the flywheel.
2. Tighten the pressure plate bolts in two stages. zStage 1: Tighten the bolts to 45 Nm (33 lb- ft).
z Stage 2: Tighten the bolts an additional 60 degrees. Klj . 3 ba
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REMOVAL AND INSTALLATION
Pilot Bearing
1. Remove the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate — 3.8L and 4.6L (2V) Engines or
Disc and Pressure Plate — 4.6L (4V) Engine
in this section.
2. Using the special tool, remove the pilot bearing from the flywheel.
Installation 1. Insert the pilot bearing into the crankshaft.
2. Install the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate — 3.8L and 4.6L (2V) Engines or
Disc and Pressure Plate — 4.6L (4V) Engine in
this section.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Special Tool(s)
Puller with Slide Hammer
308-
001 (T58L-101- B) Klj . 1 ba
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REMOVAL AND INSTALLATION
Flywheel Ring Gear
Removal
1. Remove the flywheel. For additional information, refer to Section 303 - 01A ,
Section 303 - 01B or
Section 303 - 01C .
2. WARNING: This procedure should be carried out only by a correctly equipped and
experienced acetylene torch operator. Tongs must be used or asbestos gloves worn
when handling the heated flywheel ring gear. Failure to follow these instructions can
result in personal injury.
CAUTION: Tap the flywheel ring gear evenly to prevent binding.
Remove the flywheel ring gear from the flywheel. zEvenly heat the flywheel ring gear with an acetylene torch and use a brass drift to drive
the flywheel ring gear off the flywheel.
Installation
1. WARNING: This procedure should be carried out only by a properly equipped and
experienced acetylene torch operator. Tongs must be used or asbestos gloves worn
when handling the heated flywheel ring gear. Failure to follow these instructions can
result in personal injury.
CAUTION: Do not heat the flywheel ring gear beyond 261°C (500°F). Use heat-
indicating crayons to prevent overheating.
CAUTION: Keep the torch moving to prevent hot spots.
Evenly heat the flywheel ring gear with an acetylene torch. zInstall the flywheel ring gear with the bevel on the flywheel ring gear facing the rear of the
flywheel.
z Use a brass drift to tap the flywheel ring gear into position, reheat as necessary.
2. Install the flywheel. For additional information, refer to Section 303 - 01A ,
Section 303 - 01B or
Section 303 - 01C . SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Clutch System
System adjustment Self adjusting
Fluid and Lubricant
Super Premium SAE 10W-30
XO- 10W-30- BSP WSS-
M2C153- G
Torque Specifications Description Nm lb-
ft lb-
in Brake booster nuts 25 18 —
Brake pedal support bracket to cowl bolt 25 18 —
Clutch pedal retaining nut 40 30 —
Clutch release lever cable bracket screw (3.8L) 10 — 89
Clutch release lever cable to bulkhead screws 4 — 35
Clutch release lever cable to crossmember retaining screw 8 — 71
Clutch release lever cable to master cylinder retaining screw (4.6L) 8 — 71
Instrument panel reinforcement screws 9 — 80
Instrument panel steering column cover screws 9 — 80 Klj . 1 ba
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DESCRIPTION AND OPERATION
Clutch Controls
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual Item Part Number Description
1 7535 Clutch release lever cable (3.8L)
2 7535 Clutch release lever cable (4.6L)
3 11A152 Clutch pedal position (CPP) switch Klj . 1 ba
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