Changing the clutch in your Ford F-150 is relatively simple. You’ll need at least 2 hours to change your clutch. You should change the clutch in your F-150 about every 100,000 miles. You may need to do this more often if the clutch plate shows wear or the clutch fails completely.
Remove the Old Clutch
1. Remove the exterior parts (those that are not in the engine compartment) to include the floor shifter inside the cab of your F-150 and the exhaust pipe.
2. Remove interior parts–those parts that are under the hood. This includes the starter, which is attached to the transmission bell-housing. Disconnect the drive-shaft of your F-150 and the hose for your truck’s hydraulic slave cylinder.
3. Remove the transmission from your F-150. Using a metric socket set, undo the transmission cross-member and bolts, which will allow you to remove the transmission from the truck. You should have plenty of room to work underneath your F-150, as these are tall trucks. In some cases, especially if your truck is lowered, consider using a lift or a jack to raise your truck off the ground for easy access to all components.
4. Remove the pressure plate and the worn clutch disk from the transmission.
5. Inspect the flywheel. If the clutch flywheel shows significant amounts of wear or is damaged in any way, you should replace it. Reusing a damaged flywheel can cause your new clutch to fail.
Install the New Clutch
6. Install your new clutch disk and pressure plate. You’ll need to use the clutch alignment tool, which should come as part of your clutch kit. If your clutch kit doesn’t include this tool, you can buy it at an auto parts store or any Ford dealership.
7. Replace the transmission back into your F-150. Remember to reconnect the transmission cross-member and all bolts.
8. Reconnect all interior parts–including the starter, drive-shaft and the hose for the hydraulic slave cylinder. Don’t forget to bleed the slave cylinder when you attach the hose.
9. Reconnect the exterior parts, which includes the exhaust pipe and the gearshift inside the cab.
10. Drive your F-150 slowly in a controlled environment. This will ensure that the new clutch is installed properly and is in good working condition.