Ford Fairmont, Mercury Zephyr Repair Manual 1978-1983

THERMOSTAT | REMOVAL AND INSTALLATION
(See figures 38 and 39)

1. Open the valve and drain the radiator so the coolant level is below the coolant outlet elbow, which houses the thermostat.



2. Remove the outlet elbow retaining bolts and position the elbow sufficiently clear of the intake manifold or cylinder head to provide access to the thermostat.



3. Remove the thermostat and gasket.


TO INSTALL


4. Clean the mating surfaces of the outlet elbow and the engine to remove all old gasket material and sealer. Coat the new gasket with water-resistant sealer and install it on the engine. Install the thermostat in the outer elbow. The thermostat must be rotated clockwise to lock it in position.



5. Install the outlet elbow and retaining bolts in the engine. Tighten the bolts to 12-15 ft. lbs.



6. Refill the radiator. Run the engine at operating temperature and check for leaks. Recheck the coolant level.

DRIVEN DISC AND PRESSURE PLATE | REMOVAL AND INSTALLATION

4-CYLINDER MODELS (See Figures 8 and 9 pg. 10)

1. Disconnect the negative battery cable from the battery. Raise the vehicle and support on jack stands.



2. Remove the dust shield and return spring.



3. Loosen the clutch cable lock and adjusting nut. Remove the rubber cable plug and disconnect the cable from the release lever.



4. Remove the retaining clip and remove the clutch cable from the flywheel housing.



5. Remove the starter electrical cable and the starter motor from the flywheel housing.



6. Remove the bolts that secure the engine rear plate to the front lower part of the flywheel housing.



7. Remove the transmission flywheel housing.



8. Remove the clutch release lever from the housing by pulling it through the window in the housing until the retainer spring is disengaged from the pivot. Inspect the clutch release bearing and replace it if required.
   
   If the original bearing is reused, note the orientation, match mark it and install in the same position.



9. Loosen the six pressure plate cover attaching bolts evenly to release the spring tension gradually to avoid distorting the cover.
   
   If the same pressure plate and cover are to be reinstalled, match mark the cover and flywheel so that the pressure plate can be reinstalled in its original position.
   
   Remove the pressure plate and clutch disc from the flywheel.


TO INSTALL


10. Install the clutch release lever if it was removed.



11. Position the clutch disc and pressure plate assembly on the flywheel. The three dowel pins on the flywheel must be properly aligned with the pressure plate.
    
    Bent, damaged or missing dowels must be replaced. Start the cover attaching bolts but do not tighten them.
    
    Avoid touching the clutch disc face, dropping parts or contaminating parts with oil or grease.



12. Align the clutch disc using the proper alignment tool inserted in the pilot bearing. Alternately tighten the cover bolts to specification. Remove the alignment tool.



13. Apply a light film of lithium base grease to (1) the outside diameter of the transmission front bearing retainer, (2) the release lever bearing fork and anti-rattle spring where they contact the release bearing hub, and (3) to the release bearing surface that contacts the pressure plate release fingers.
    
    Then, fill the grease groove of the release bearing hub with the same grease.
    
    Clean all excess grease from inside the bore of the bearing hub, otherwise, excess grease will be forced onto the spline by the transmission input shaft bearing retainer, and will contaminate the clutch disc.



14. Attach the clutch release bearing to the release lever.



15. Attach the release lever and release bearing to the flywheel housing.

• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams