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Forward Clutch: Assembly

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air.
  2. Install new forward clutch piston seals.
    1. Install the forward clutch piston outer seal.
    2. Install forward clutch cushion spring.
    3. Install the forward clutch piston inner seal.
      Fig 1: Installing New Forward Clutch Piston Seals
      G03975357Courtesy of FORD MOTOR CO.
    3. NOTE: Lubricate the forward clutch piston inner and outer seal with clean automatic transmission fluid.
  3. Install lip seal protector tools on the forward clutch piston.
    1. Install the special tool to the forward clutch piston outer seal.
    2. Install the special tool to the forward clutch piston inner seal.
      Fig 2: Installing Lip Seal Protector Tools On Forward Clutch Piston
      G03975358Courtesy of FORD MOTOR CO.
    4. CAUTION: Care must be taken to prevent damage to the seals.
  4. As you install the forward clutch piston into the forward clutch cylinder, remove the special tools.
  5. Install the 15 forward clutch piston springs and the forward clutch piston spring retainer.
    1. Install the 15 forward clutch piston springs.
    2. Install the forward clutch piston springs retainer.
      Fig 3: Installing Forward Clutch Piston Springs & Forward Clutch Piston Spring Retainer
      G03975359Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not fully depress the special tool or damage to the spring retainer can occur.
    Fig 4: Installing Forward Clutch Piston Spring Retaining Ring
    G03975360Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the forward clutch piston spring retaining ring.
    7. CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise (I.D. to O.D.) and the word "TOP" facing up.
    CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.
    Fig 5: Ensuring The Word "TOP" Is Facing Up
    G03975361Courtesy of FORD MOTOR CO.
  7. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
  8. Install the steel clutch plates and friction clutch plates (quantity model dependent) in alternating order starting with a steel clutch plate.
    Fig 6: Installing Steel Clutch Plates And Friction Clutch Plates
    G03975362Courtesy of FORD MOTOR CO.
    9. CAUTION: The retaining ring is a select fit.
  9. Install the forward clutch pressure plate and the original selective retaining ring.
    1. Install the forward clutch pressure plate.
    2. Install the forward clutch retaining ring.
      Fig 7: Installing Forward Clutch Pressure Plate And Forward Clutch Retaining Ring
      G03975363Courtesy of FORD MOTOR CO.
    10. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.
  10. Air check the forward clutch piston.
    1. Place the forward clutch cylinder with forward clutch piston facing down.
    2. Install the transmission center support on the forward clutch cylinder.
    3. Apply air pressure to the left port of the center support.
      Fig 8: Air Checking Forward Clutch Piston
      G03975364Courtesy of FORD MOTOR CO.
  11. Check forward clutch disc pack free play.
    1. Press down on forward clutch disc pack.
    2. Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.
      • If the clearance is not within specifications, install the correct size retaining ring.
        Fig 9: Checking Forward Clutch Disc Pack Free Play
        G03975365Courtesy of FORD MOTOR CO.
        FORWARD CLUTCH RETAINING RING THICKNESS CHART

        Part Number Thickness Diameter
        E860126-S 1.37 mm (0.0539 in) 125.1 mm (4.925 in)
        E860127-S 1.73 mm (0.0681 in) 125.1 mm (4.925 in)
        E860117-S 2.08 mm (0.0819 in) 125.1 mm (4.925 in)
        E860118-S 2.44 mm (0.0961 in) 125.1 mm (4.925 in)
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