Just did mine today. Yes you have to remove the clutch. It's about a 15 min job. I also have 235K and wouold have changed the clutch but our local O'Reillys didn't have one. The old one is a little worn so I'll get one at the Napa store by work.
Glassdude,does the AC compressor still cycle on and off normally after the shim removal? My 02 Excursion is due for a freon top off or a straight up pull down and recharge.
Yes it does. I am still going to get a new clutch because mine did look a little worn. I didn't check the air gap with a guage but I could see before removing the shim the air gap was almost 1/8.