Ford Falcon. Manual - part 254

308-01-3 Clutch 308-01-3

DESCRIPTION AND OPERATION

Clutch

Introduction

Three clutch variants are used across the manual BA

Falcon range. All manual I-6 vehicles, except XR6T

are fitted with a one-piece flywheel and 254mm

clutch. Manual XR6T vehicles are fitted with a

two-piece flywheel and a heavy-duty 267mm clutch.

All manual V8 vehicles are fitted with a one-piece

flywheel, 292mm pressure plate and 280mm clutch

disc to provide a high torque capacity.

Clutch Function

The primary function of the clutch system is to

connect and disconnect engine power to the

transmission upon driver command.

Clutch System Components — STD I6

Item

Description

Item

Description

4

Clutch pressure plate

1

Flywheel

5

Clutch slave cylinder/clutch release hub

2

Transmission input shaft pilot bearing

and bearing

3

Clutch disc

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308-01-4 Clutch 308-01-4

DESCRIPTION AND OPERATION (Continued)

Clutch System Components —XR6 Turbo

Item

Description

1

Flywheel (2 piece assembly)

2

Transmission input shaft pilot bearing

3

Clutch disc

4

Clutch pressure plate

5

Clutch slave cylinder/clutch release hub

and bearing

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308-01-5 Clutch 308-01-5

DESCRIPTION AND OPERATION (Continued)

Clutch System Components — V8 Standard

(3 valve) & XR8 (4 Valve)

A pilot bearing supports the end of the input shaft.

Item

Description

The bearing does not require lubrication unless the

1

Flywheel

clutch system is serviced.

2

Transmission input shaft pilot bearing

The clutch does not require pressure plate re-setting

3

Clutch disc

after disasembly or disc renewal.

4

Clutch pressure plate

NOTE: The clutch pressure plate should always be

adjusted before installation.

5

Clutch slave cylinder/clutch release hub

and bearing

For Standard I6, XR6 & all V8:
The clutch is a single plate, dry friction clutch disc with

a self-adjusting, diaphragm-style spring clutch

pressure plate.

The clutch operating mechanism consists of a clutch

slave cylinder with an integral release bearing.
A pilot bearing supports the end of the input shaft.

The bearing does not require lubrication unless the

clutch system is serviced.
The clutch does not require pressure plate re-setting

after disasembly or disc renewal.

For XR6 Turbo:
The clutch is a single plate, dry friction clutch disc with

diaphragm-style spring clutch plate.

The clutch operating mechanism consists of a clutch

slave cylinder with an integral release bearing.

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308-01-6 Clutch 308-01-6

DIAGNOSIS AND TESTING

Clutch

Symptom Chart

Condition

Source

Action

  Clutch does not disengage correctly

Worn clutch disc.

  Replace worn or defective parts

Failed pressure plate.

  Replace pressure plate

Self Adjusting Clutch (SAC) over

  Remove SAC and reset

adjusted.

Air in hydraulic system

  Bleed hydraulic system

Damaged Concentric Slave Cylinder

  Repair or replace CSC. Refer to

(CSC).

Section 308-02.

  Clutch pedal hang-up or excessive

  Repair or replace CSC. Refer to

CSC damaged.

clutch pedal effort

Section 308-02.

Master cylinder damaged.

  Replace clutch master cylinder

  Noisy clutch operation when engine

  Replace CSC. Refer to Section

CSC bearing failure

running

308-02.

Clutch disc damaged

  Replace clutch disc

  Lubricate with engine oil or replace

  Noisy clutch operation with engine off

Binding at pedal support bracket

support bracket bushing

  Replace CSC. Refer to Section

CSC damaged

308-02.

Binding within pressure plate

  Lubricate pressure plate pins

Worn or contaminated clutch lining

  Replace defective part. (If grease or oil

  Clutch slips or chatters

Grease or oil on clutch facings from:

is causing the clutch to slip, replace

Release bearing

the disc, remove the grease or oil from

Engine

the pressure plate and flywheel and

CSC

reuse if it is not burned or scored.)

Pilot bearing

Repair source of leakage.

Transmission

Weak or failed pressure plate

  Replace pressure plate

Loose pressure plate to flywheel bolts

  Torque bolts to spec

Loose engine mount bolts

  Torque bolts to spec

  Replace CSC. Refer to Section

Damaged CSC

308-02.

Failed master cylinder

  Replace clutch master cylinder

  Intermittent squawk

Flywheel housing misalignment

  Replace flywheel housing

  Clutch noisy when disengaged (Engine

Pilot bearing worn

  Replace pilot bearing

running)

  Replace CSC. Refer to Section

CSC bearing worn

308-02.

  Clutch spin or drag

Failed pressure plate

  Replace pressure plate

  Replace clutch disc and degrease

Grease on linings of clutch disc

pressure plate and flywheel

Flywheel housing out of alignment

  Align to specifications

SAC over adjusted

  Remove SAC and reset

  Fit clutch disc correctly, if damaged

Damaged clutch disc

replace

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