M5R2 Clutch kit help

[FNG]

Alright, at the risk of sounding like a complete newb, the 27mm shaft diameter = 1-1/16”. The clutches that were 1-1/8” obviously worked, but The 1-1/16 would not spline in easily. Should it be pretty tough to place it? I’ve replaced the clutch in both of my 03 Cobras, and I don’t recall it being difficult to place the clutch plate onto the input shaft like this.

 

[FNG]

I say easily… as in I attempted to moderately force it and it would not go in.

 

[85_Ranger4x4]

I have the 4.2 R2 out of an '04 Heritage F-150 and the clutch kit for a '96 F-150 fit perfectly.

4.2 uses a smaller clutch/flywheel than the 5.0, it uses the 157t seperator plate between the engine and trans where the 5.0 flywheel/starter needs the 164t.

I ran into the different flywheel thing with the seperator plate on mine, clutch went together great though.

SBF Engine Seperator Plates

The whole thing came about when I tried to reuse the 4.2 seperator plate I got with my M5ODR2 with a '96 302 starter. The starter hole was just barely too small. The plate from my C5 was identical but didn't have a neat little foam seal around the crank. Faced with the rather terrifying...

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