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Clutch Assembly: Installation

  1. Lightly coat input shaft splines, release bearing and fork contact areas with molybdenum disulfide grease. Align clutch cover dowel holes with flywheel dowels. Tighten clutch cover-to- flywheel bolts evenly in a crisscross pattern to specification. See TORQUE SPECIFICATIONS  at end of article.
  2. Place a wooden block on jack, and position jack under front of oil pan. Raise front of engine to ease transmission installation. Install transmission. Tighten clutch housing-to-engine block bolts to specification. Place jack (from front of engine) under transmission.
  3. Raise transmission until it is level with engine. Position Power Plant Frame (PPF) in place. Install PPF/differential mounting spacer, and tighten bolts to 27-38 ft. lbs. (37-52 N.m). Install and tighten PPF-to-transmission side mounting bolts.
    NOTE: On Miata, front PPF-to-differential side mounting bolt is considered reamer bolt and is used to align frame.
  4. Ensure sleeve is installed into PPF housing block. Install spacer and bolts. Ensure reamer bolt is installed into front hole, and tighten bolt. See Figure .
  5. Install transmission-to-PPF bracket. Install remaining PPF bolts, and tighten to specification. See TORQUE SPECIFICATIONS  . To complete installation, reverse removal procedure.


  1. Place clutch disc on flywheel. Place pressure plate on flywheel and align reference marks. Tighten bolts evenly in a crisscross sequence.
  2. Raise transmission into position. Install transmission-to-engine block bolts. Install crossmember. Install new transfer case-to-extension housing gasket. Install transfer case.
  3. Tighten transfer case-to-extension housing bolts in sequence. See Fig 1 . Tighten bolts to specification. See TORQUE SPECIFICATIONS  at end of article. To complete installation, reverse removal procedure.
    NOTE: When installing shift lever assembly, always tighten large bolt first.
  4. Bleed hydraulic clutch system. See HYDRAULIC SYSTEM BLEEDING  . Fill transfer case with 1.3 qts. (1.2L) of Mercon ATF. Fill transmission with 85W-90 gear oil.
Fig 1: Navajo Transfer Case-To-Extension Housing Tightening Sequence
G90H15492Courtesy of FORD MOTOR CO.
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