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Replacing the clutch, pressure plate, throwout bearing, and pilot bearing on 1994 Ford Ranger XLT with Hydraulic Clutch


When making some adjustments on a vehicle I know how important it is to have detailed information to make the project much easier. While you are waiting for your expert answer, I did manage to find a link that will provide you with some good information. I am also adding a second link that will provide you with some good information to help you with finding the manual for your vehicle to make sure you get the correct oil for your vehicle. I hope my links are useful.

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Joseph P. -
May 24, 2011



Clutch Disc and Clutch Pressure Plate SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Clutch Coupling Tool T88T-70522-A Clutch Aligner T74P-7137-K


Disconnect the battery negative cable. Disconnect clutch hydraulic system master cylinder push rod from clutch pedal (7519) . Raise the vehicle on a hoist and position suitable safety stands under vehicle. Remove starter motor (11001) . Disconnect the hydraulic coupling at transmission with Clutch Coupling Tool T88T-70522-A. Slide the white plastic sleeve toward clutch slave cylinder, and apply a slight tug on tube. Remove transmission (7003) . Check pressure plate finger height variations before removing.

Clutch Disc and Clutch Pressure Plate Installation, Typical

Item Part Number Description 1 6375 Flywheel 2 7003 Transmission 3 7A508 Clutch Slave Cylinder 4 N605905-S Bolt. Tighten to 19-26 Nm (14-19 Ft-Lb) 5 7563 Clutch Pressure Plate 6 N802096-S2 Bolt. Tighten to 21-32 Nm (15-24 Ft-Lb) 7 7550 Clutch Disc 8 7118 Mainshaft Bearing Roller 9 7K578 Dowel Pin

Mark assembly position of clutch pressure plate and cover to flywheel (6375) if installing original components. CAUTION: If cover and plate are to be reinstalled, bolts must be removed evenly or permanent damage to diaphragm spring will occur causing clutch to not release fully.

Loosen clutch pressure plate and cover attaching bolts evenly until clutch pressure plate diaphragm spring is expanded. Remove bolts. Remove clutch pressure plate , cover and clutch disc from flywheel .


NOTE: Clean clutch pressure plate and flywheel with a suitable commercial alcohol base solvent so surfaces are free from any oil film.

NOTE: Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in the solvent.

Position clutch disc on flywheel so Clutch Aligner T74P-7137-K can enter clutch bearing (7025) and align clutch disc .

When installing original clutch pressure plate and cover, align assembly and flywheel with marks made during removal and with dowels on flywheel. Position clutch pressure plate and cover on flywheel and dowels. Align the clutch pressure plate and clutch disc . Install assembly bolts to flywheel . Tighten bolts to 21-32 Nm (15-24 ft-lb) in sequence shown. Remove clutch aligner tool.

Install transmission . Refer to Section 07-03. Connect coupling by pushing the male coupling into female coupling of clutch slave cylinder. Connect hydraulic clutch master cylinder push rod to clutch pedal . NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

Connect battery negative cable. Bleed clutch system if required.

Bleed Procedure NOTE: When installing dry clutch master cylinder or tube service parts, use alternate bleed procedure (bench bleeding).

SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Clutch Coupling Tool T88T-70522-A

Under normal conditions, disconnecting the clutch coupling will not introduce air into the system. However, if there appears to be air in the system (spongy clutch pedal , or insufficient bearing travel), the system must be bled. The following procedure is used with the hydraulic system installed on the vehicle.

Disconnect the coupling at the transmission with Clutch Coupling Tool T88T-70522-A by sliding the white plastic sleeve toward the clutch slave cylinder while applying a slight tug on the clutch tube. Clean dirt and grease from around the clutch master cylinder reservoir cap. Remove cap and diaphragm and fill reservoir to the step with Heavy Duty Brake Fluid C6AZ-19542-AA or -BA (ESA-M6C25-A) or equivalent. Brake fluid must be certified to DOT 3 specification. Using a small screwdriver, depress the internal mechanism of the male coupling to open the valve. While continuing to hold the valve open, slowly depress the clutch pedal to the floor and hold. Remove the screwdriver from the coupling, closing the valve. Release the clutch pedal . NOTE: The clutch master cylinder reservoir must be kept full at all times to ensure that there will be no additional introduction of air to the system.

Refill reservoir to level at step. Repeat above three steps. Close reservoir. Reconnect the coupling to the clutch slave cylinder. Check that the connection is secure by applying a slight tug to the clutch tube. Stroke the clutch pedal as rapidly as possible for 5 to 10 strokes. Wait 1 to 3 minutes. Repeat above two steps three more times. Loosen bleed screw (located in the clutch slave cylinder next to the inlet connection). Depress and hold clutch pedal while tightening bleed screw to 3-5 Nm (2.2-3.7 ft-lb). Refill clutch master cylinder reservoir to level at step. The hydraulic system should now be fully bled and should properly release the clutch. Check clutch reserve as described in this section. If system still has air in it, use the alternate bench bleeding procedure. Bench Bleed

The downward angle of the clutch master cylinder makes it difficult for air to escape up into the reservoir. Therefore, if the clutch master cylinder is removed from the vehicle and bled while held in a vertical orientation (a bench bleed), air can escape much more efficiently.

Clutch Slave Cylinder

Start with tube and reservoir attached to clutch master cylinder , but system removed from vehicle. Lightly clamp reservoir in a vise. Hold the clutch master cylinder vertically with reservoir feed hose in the highest position on the body. Fill reservoir and extend above clutch master cylinder and make sure the quick connect on clutch line is below the clutch master cylinder . Using a small screwdriver, depress the internal mechanism of the male quick connect coupling to open the valve. Stroke and hold master cylinder push rod. Close quick connect valve. Release master cylinder push rod. Fill reservoir. Repeat Steps 4 through 8 four more times. With the clutch master cylinder still being held with the outlet tube and reservoir feed tube ends high, quick connect closed and the reservoir full, push the push rod into the body several times quickly to expel any remaining air. (If remote reservoir, pinch supply hose with fingers two or three times to help move air into reservoir.) When the movement of the push rod is 4mm (.160 inch) or less when stroked in Step 10 above, the clutch master cylinder may be reinstalled into the vehicle and coupled to the concentric clutch slave cylinder.

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MikeLangton -
Sears Technician
June 01, 2011
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