CLUTCH AND FLYWHEEL INSTALL - FOCUS ST

Introduction

This tutorial provides a comprehensive guide to installing a lightweight flywheel and clutch in a Ford Focus ST. These components are essential for enhancing your vehicle's performance. While some mechanical knowledge is beneficial, this task can be accomplished at home with minimal tools.

Step 1: Prepare the Vehicle

• Ensure the vehicle is parked on a level surface and secure it with wheel chocks.
• Disconnect the negative battery terminal to prevent any electrical issues while working on the car.
• Remove the front cowl by:
  • Removing the wipers (15mm nuts).
  • Taking out the Torx screws (T30) on either side.

Step 2: Remove the Intake and Battery

• Remove the air intake system:
  • Disconnect any sensors or clamps.
  • Remove the entire airbox or intake filter assembly.
• Remove the battery:
  • Disconnect the positive terminal followed by the negative terminal.
  • Remove any battery tie-downs and pull the battery out.

Step 3: Access the Transmission

• Remove the necessary components to access the transmission:
  • Disconnect the starter (13mm bolts) and shift linkage (use a flathead screwdriver to pop off the connectors).
  • Disconnect the clutch slave line, keeping it elevated to prevent fluid loss.
• Remove both front axles:
  • Remove the axle nuts (32mm) and lower control arm bolts (T55).
  • Carefully separate the lower control arms from the steering knuckles.

Step 4: Drain Transmission Fluid

• Before removing the transmission, drain the fluid:
  • Remove the fill plug before the drain plug to prevent vacuum formation.

Step 5: Remove the Transmission

• Support the engine and transmission with a jack.
• Remove the transmission mount bolts and bell housing bolts (note their locations for reassembly).
• Carefully lower the transmission and remove it from the vehicle.

Step 6: Replace the Flywheel and Clutch

• Inspect the old clutch and flywheel for damage.
• Remove the old flywheel using the appropriate Torx sockets.
• Clean the surface of the engine where the new flywheel will mount.
• Install the new flywheel:
  • Apply Loctite to the bolts and torque them to the manufacturer's specifications.
• Install the new clutch:
  • Ensure the clutch disc is oriented correctly (springs facing the pressure plate).
  • Use a clutch alignment tool to properly align the disc.

Step 7: Reinstall the Transmission

• Lift the transmission back into place, ensuring it aligns with the new clutch.
• Reinstall all bell housing and transmission mount bolts.
• Reconnect the shift linkage and starter.

Step 8: Reassemble Vehicle Components

• Reinstall the front axles, ensuring everything is tightened and secure.
• Reconnect the battery, intake, and any other components that were removed.
• Reinstall the cowl and wipers, ensuring they are in the correct position.

Step 9: Bleed the Clutch

• To bleed the clutch, use an 11mm wrench on the slave cylinder's bleed nipple:
  • Have an assistant pump the clutch pedal and hold it down while you open the bleed nipple.
  • Close the nipple before your assistant releases the pedal. Repeat until no air bubbles appear.

Conclusion

You have successfully installed a lightweight flywheel and clutch in your Focus ST. Remember to break in the new clutch gently for the first 500 miles. Regularly check your vehicle for any leaks or issues after the installation. For further modifications or maintenance, consider consulting a professional or watching additional tutorials.