Installing a Luk clutch kit involves a series of steps to ensure proper functionality and longevity of the system. This guide details the process, primarily focusing on Ford 1999-2003 Super Duty applications, as outlined in available documentation. The process requires specific tools and attention to detail, and a helper or access to a vehicle lift is recommended. The upgrade is often performed to prevent potential damage to the transmission and improve clutch feel.
Preparation and Removal of the Old Clutch
Before beginning the installation, it is crucial to gather the necessary tools and equipment. These include a torque wrench, socket set, ratchet, clutch alignment tool (provided in the kit), and a jack with jack stands. Disconnecting the negative battery cable is the first step to ensure electrical safety. For vehicles equipped with a shift lever, removing the rubber boot and associated screws provides access to the shift lever mount, which then allows removal of the shift lever itself using Torx screws.
The removal process begins with detaching the transmission. Once the transmission is removed, the old clutch and pressure plate can be accessed. These components are secured with bolts that must be removed using a socket and ratchet. Care should be taken not to damage the flywheel during this process. The flywheel itself is a heavy component and requires careful handling. Inspection of the removed components is recommended; documentation indicates that while the flywheel and pressure plate may be in good condition, the clutch disc often shows signs of wear, such as a loose center hub or disintegrating washers.
Flywheel Preparation and New Clutch Installation
After removing the old clutch components, the flywheel requires thorough cleaning with a wire brush to remove any oil or grease residues. The new pilot bearing must then be installed into the flywheel, driven in until it reaches a stop. Caution is advised during this step to avoid damaging the new bearing.
The Luk clutch kit includes a new clutch disc and pressure plate. The new clutch disc is installed onto the flywheel using the clutch alignment tool, ensuring it is centered and aligned correctly. The pressure plate is then installed onto the flywheel, and the bolts are tightened evenly using a torque wrench. A star pattern should be followed when tightening the pressure plate bolts to ensure uniform pressure. The documentation specifies a torque range of 15-20 lb/ft for the pressure plate bolts. Once the pressure plate is secured, the clutch alignment tool can be removed.
Component Replacement and Additional Considerations
The Luk clutch upgrade kit includes several components beyond the clutch disc and pressure plate. These include a new flywheel, release bearing, pilot bearing, alignment tool, and upgrade tag. New bolts for both the flywheel and pressure plate are also provided; it is explicitly stated that the old bolts should not be reused. The documentation also recommends considering the replacement of the clutch fork with a newer, heavier-duty design, as reports of stock fork failures have been noted.
Additional components that may be beneficial to replace during the installation include the gasket between the transfer case and transmission (Ford P/N E7TZ-7086-A) and the clutch fork anchor stud (Ford P/N F81Z-7B602-AA). While the gasket is not strictly necessary, it can help prevent leaks. Both of these parts are relatively inexpensive.
Transmission Reinstallation and Final Steps
With the new clutch components installed, the transmission can be reinstalled. Before reinstalling the transmission, it is important to remember the original installation of the clutch release bearing within the fork. The old fork and its mounting stud should be removed and inspected. The input shaft of the transmission should be checked for burrs or excessive wear, as any issues here may require major transmission repair.
After reinstalling the transmission, the mating surfaces between the transmission and gear selector should be cleaned. A small bead of gasket maker can be applied to the gear selector housing before reinstalling it into the transmission, and the bolts should be torqued to 17 lb/ft. The shift lever can then be reinstalled and secured with the appropriate torque (21 lb/ft). The shift lever boot is then reattached.
Torque Specifications and Final Checks
Specific torque specifications are critical for a successful installation. The flywheel bolts should be torqued to 87-91 lb/ft, but it is noted that this specification may vary depending on the specific Luk upgrade kit (07-155 LuK upgrade kit requires this torque). The documentation emphasizes the importance of using the correct torque specifications for the particular kit being installed.
Finally, the negative battery terminal connections should be reconnected. The vehicle should be started, and the clutch operation should be checked. Transmission cooler lines should be inspected for leaks, and the proper operation of the transfer case should be verified. The initial operation of the new clutch is expected to exhibit reduced pedal effort and smoother engagement. A break-in period of gentle driving for the first few hundred miles is recommended.
Conclusion
The installation of a Luk clutch kit, particularly in Ford Super Duty vehicles, is a detailed process that requires careful attention to each step. Proper preparation, adherence to torque specifications, and consideration of additional component replacements contribute to a successful installation and improved clutch performance. The upgrade can address issues with stock clutch feel and prevent potential transmission damage.