How to install flywheel ford f150 6 cylinder engine

1. Remove the starter.
2. Remove the transmission from the vehicle, following the procedures in Section 7.
3. On a manual shift transmission, remove the pressure plate and cover assembly and the clutch disc following the procedure in Section 7.
4. Remove the flywheel attaching bolts and remove the flywheel and engine rear cover plate.
5. Use an awl to punch two holes in the crankshaft rear oil seal. Punch the holes on opposite sides of the crankshaft and just above the bearing cap to cylinder block split line. Install a sheet metal screw in each hole. Use two large screwdrivers or small pry bars and pry against both screws at the same time to remove the crankshaft rear oil seal. It may be necessary to place small blocks of wood against the cylinder block to provide a fulcrum point for the pry bars. Use caution throughout this procedure to avoid scratching or otherwise damaging the crankshaft oil seal surface. To install:
   
6. Clean the oil seal recess in the cylinder block and main bearing cap.
7. Clean, inspect and polish the rear oil seal rubbing surface on the crankshaft. Coat a new oil seal and the crankshaft with a light film of engine oil. Start the seal in the recess with the seal lip facing forward and install it with a seal driver. Keep the tool, T82L-6701-A (4-cyl. engines) or T72C-6165 (6-cyl. engine) straight with the centerline of the crankshaft and install the seal until the tool contacts the cylinder block surface. Remove the tool and inspect the seal to be sure it was not damaged during installation.
8. Install the engine rear cover plate. Position the flywheel on the crankshaft flange. Coat the threads of the flywheel attaching bolts with oil-resistant sealer and install the bolts. Tighten the bolts in sequence across from each other to the specifications listed in the torque chart in this section.
9. On a manual shift transmission, install the clutch disc and the pressure plate assembly following the procedure in Section 7.
10. Install the transmission, following the procedure in Section 7.

1. Disconnect both battery cables, negative cable first.
2. Remove the battery and battery tray.
3. Remove the engine air cleaner tube and the air intake resonator.
4. Disconnect the speedometer cable at the transaxle.
5. Remove the slave cylinder line-to- slave cylinder hose retaining clip, then disconnect the slave cylinder line from the slave cylinder hose and plug the hose.
6. Disconnect the ground strap from the transaxle.
7. Remove the tie wrap and unplug the three electrical connectors located above the transaxle.
8. Remove the electrical connector support bracket.
9. Install Engine Support Bar 014-00750 or equivalent, and attach it to the engine lifting eyes with suitable chains or cables.

Fig. 1: Install a suitable engine support bar and attach it to the engine lifting eyes-1.8L and 1.9L engines

1. If equipped, remove the three nuts from the left-hand engine support bracket.
2. Loosen the mount pivot nut and rotate the mount out of the way.
3. Remove the three bolts and the left-hand engine support mount.
4. Remove the two upper transaxle-to-engine bolts.
5. Raise and safely support the vehicle.
6. Remove the front wheel and tire assemblies.
7. Remove the inner fender splash shields.
8. Drain the transaxle fluid and install the drain plug.
9. Remove the halfshafts.
10. Install Transaxle Plugs T88C-7025-AH or equivalent, between the differential side gears.
    

1. If equipped with the 1.8L engine, remove the intake manifold support bolts and the support.
2. Remove the starter motor.
3. Unfasten the gearshift stabilizer bar nut and washers. Remove the stabilizer bar and bracket from the transaxle.
4. Unfasten the shift control rod-to-transaxle bolt and nut and remove the shift control rod from the transaxle.
5. Remove both lower splash shields.
6. Unfasten the transaxle mount-to-crossmember bolts and nuts and remove the lower crossmember (rear engine support).
7. Position and secure a suitable transaxle jack under the transaxle.
8. Remove the front transaxle mount and bracket.

Fig. 2: Removing the front transaxle mount and bracket-1.8L and 1.9L engines

1. Remove the lower engine-to-transaxle bolts and slowly lower the transaxle out of the vehicle.

1. If the clutch assembly is to be reused, matchmark the pressure plate and the flywheel so they can be assembled in the same position.
   
2. Install flywheel holding tool T84P-6375-A or equivalent, in a transaxle mounting hole on the engine and engage the tooth of the holding tool into the flywheel ring gear.

Fig. 1: Install a flywheel holding tool in a transaxle mounting hole on the engine, and engage the tooth of the tool into the flywheel ring gear

1. Loosen the pressure plate-to-flywheel retaining bolts one turn at a time, in a crisscross pattern, until the spring tension is relieved, to prevent pressure plate cover distortion.
2. Support the pressure plate and unfasten the retaining bolts. Remove the pressure plate and clutch disc from the flywheel.

1. Inspect the flywheel, clutch disc, pressure plate, release bearing, pilot bearing and the clutch fork for wear. Replace parts as needed.

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Remove the transaxle assembly.
4. If the clutch assembly is to be reused, matchmark the pressure plate and the flywheel so they can be assembled in the same position.
5. Install flywheel holding tool T84P-6375-A or equivalent, in a transaxle mounting hole on the engine and engage the tooth of the holding tool into the flywheel ring gear.

1. Loosen the pressure plate-to-flywheel retaining bolts one turn at a time, in a crisscross pattern, until the spring tension is relieved, to prevent pressure plate cover distortion.
2. Support the pressure plate and unfasten the retaining bolts. Remove the pressure plate and clutch disc from the flywheel.

1. Inspect the flywheel, clutch disc, pressure plate, release bearing, pilot bearing and the clutch fork for wear. Replace parts as needed.

1. If removed, install a new pilot bearing using a suitable installation tool.
2. If removed, install the flywheel. Make sure the flywheel and crankshaft flange mating surfaces are clean. Tighten the flywheel retaining bolts to 71-76 ft. lbs. (96-103 Nm) on the 1.8L engine or 54-67 ft. lbs. (73-91 Nm) on the 1.9L engine.
3. Clean the pressure plate and flywheel surfaces thoroughly. Position the clutch disc and pressure plate into the installed position and support them with a dummy shaft or clutch aligning tool. If the clutch assembly is being reused, align the matchmarks that were made during the removal procedure.
4. Install the pressure plate-to-flywheel retaining bolts. Tighten the bolts in the correct sequence to 13-20 ft. lbs. (18-26 Nm). Remove the alignment tool.

1. If the release bearing was removed, lubricate the release fork where it contacts the bearing and install the bearing in the fork.
2. Install the transaxle assembly.
3. Lower the vehicle.
4. Bleed the hydraulic clutch system, if needed.
5. Connect the negative battery cable.
6. Road test the vehicle and check the clutch for proper operation.

1. Lift clutch pedal to uppermost position to disengage clutch and brake pedal pivot shaft.
2. Push clutch and brake pedal pivot shaft forward and unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward.
3. Raise and support vehicle.
4. Remove clutch release lever dust shield.
5. Disconnect clutch release lever cable from clutch release shaft.
6. Remove retaining clip, then clutch release lever cable from flywheel housing.
7. Remove starter motor from flywheel housing, then engine rear plate to front lower flywheel housing bolts.
8. Remove transmission.
9. Remove flywheel housing back just far enough to clear clutch pressure plate, then remove housing.
10. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring disengages from pivot.
11. Remove clutch release hub and bearing from clutch release shaft.
12. Loosen six clutch pressure plate bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate. If same clutch pressure plate is to be installed, mark plate and flywheel so pressure plate can be installed in its original position.
13. Remove clutch pressure plate and clutch disc from flywheel.

1. Position clutch disc and pressure plate assembly on flywheel, noting following:
   1. Three flywheel housing to block dowels on flywheel must be properly aligned with clutch pressure plate.
   2. Bent, damaged or missing flywheel housing to block dowels must be replaced.
   3. tart clutch pressure plate bolts but do not tighten.
   4. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
   5. Align clutch disc using suitable alignment tool inserted in pilot bearing.
   6. To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight, then tighten to specifications.
   
   
2. Install transmission to flywheel housing.
3. Install engine rear plate to flywheel front lower housing bolts, then connect clutch release cable to flywheel housing and connect retaining clip.
4. Connect clutch release lever cable to clutch release shaft, then install clutch release lever dust shield.
5. Install starter motor.
6. Lower vehicle, then install clutch release lever cable as follows:
   1. Lift clutch pedal to disengage clutch and brake pedal pivot shaft.
   2. Push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft.
   
   
7. Cycle clutch pedal several times to adjust clutch release lever cable