Parts for your 2003 Ford Falcon-Thrust bearing

2003 Ford Falcon thrust-bearing: what’s fitted and how to look after it

On a 2003 Ford Falcon (BA series), a clutch thrust/release bearing is fitted to manual-transmission models, automatic models don’t use a clutch thrust bearing at all. This is set out in the Ford BA Falcon Workshop Manual (Clutch section) and supported by the Gregory’s Ford Falcon BA Series 2002–2005 Service and Repair Manual, both of which show a release (throw-out) bearing operating the pressure plate on BA manuals (T5/T56). Tremec and BorgWarner service literature for these gearboxes also specifies inspection and replacement of the release bearing during clutch service. So, the part is relevant if the car is a manual, it’s not present on BA automatics.

On a manual BA Falcon, the thrust (release) bearing’s job is simple but critical: it transfers the driver’s pedal effort via the clutch fork or a concentric slave cylinder to the pressure plate’s diaphragm, cleanly disengaging the clutch so gears can be selected without graunching. When healthy, it runs quietly and smoothly, only loaded when the clutch pedal is pressed. If it’s worn, the driver may hear a chirp, squeal, or whir that changes when the pedal is depressed, and feel a notchiness or vibration at the pedal.

Because the bearing lives inside the bellhousing, it’s a replace-once-you’re-in-there item. The practical advice, straight from workshop practice and the factory manuals: if the gearbox is coming out for a clutch, replace the thrust bearing as part of a full clutch kit, along with the spigot/pilot bearing and any fork pivot or clip hardware. It’s cheap insurance compared with paying for labour twice. If the car uses a concentric slave/release unit, inspect for leaks and replace the whole assembly if there’s any doubt.

Servicing tips a BA Falcon owner will actually use:

• Listen for noise that appears with the pedal pressed and disappears when released—classic release bearing behaviour.
• Bleed the hydraulic system properly after clutch work, a spongy pedal can make the bearing chatter.
• When refitting, only a light smear of high-temp grease on the guide tube/contact points—keep grease well away from the friction surfaces.
• Check clutch fork alignment and pedal travel as per the manual, poor setup shortens bearing life.

Replacement requires gearbox removal, so plan the job with fresh fasteners where specified, and follow torque specs and procedures outlined in the Ford BA Falcon Workshop Manual or the Gregory’s manual. Done right, the new bearing should run quietly for many kilometres of easy shifting.

• Do automatic 2003 Ford Falcons have a thrust bearing?
  No. BA automatics use a torque converter, so there’s no clutch or clutch thrust (release) bearing fitted. Any driveline noise on an auto car will be from different components, not a clutch release bearing.
• What are the symptoms of a worn thrust bearing on a BA Falcon manual?
  A whirring, chirping, or squealing noise that appears when the clutch pedal is pressed and often disappears when it’s released. You might also feel a rough or pulsing sensation through the pedal. If the noise is present with the pedal up, look instead at the spigot bearing or gearbox input bearing.
• Should the thrust bearing be replaced with the clutch?
  Yes. Every reputable clutch job on a BA manual includes a new thrust/release bearing, and usually a spigot/pilot bearing. The extra parts cost is small compared with the labour to remove the gearbox twice.