Forward Clutch: Disassembly

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.

CAUTION: The retaining ring is a select fit. See ASSEMBLY if installation of a new ring or clutch plate pack is required.

Remove the forward clutch pressure plate.
1. Remove the forward clutch retaining ring.
2. Remove the forward clutch pressure plate.
  
  Fig 1: Removing Forward Clutch Pressure Plate And Forward Clutch Retaining Ring
  Courtesy of FORD MOTOR CO.

CAUTION: Clutch discs are directional. Note direction of grooves for installation.

Remove the forward clutch disc pack.
- Inspect the forward clutch plates for wear, damage or overheating.
  
  Fig 2: Removing Forward Clutch Disc Pack
  Courtesy of FORD MOTOR CO.

WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.

CAUTION: Do not fully depress the special tool or damage to the spring retainer may occur.

Fig 3: Removing Forward Clutch Piston Retaining Ring

Courtesy of FORD MOTOR CO.

Using the special tool, remove the forward clutch piston retaining ring.
Relieve the forward clutch spring tension and remove the special tool.
Remove the forward clutch piston spring retainer and 15 forward clutch piston springs.
1. Remove the forward clutch piston spring retainer.
2. Remove the 15 forward clutch piston springs.
  - Inspect the forward clutch piston springs for distortion.
    
    Fig 4: Removing Forward Clutch Piston Spring Retainer And Forward Clutch Piston Springs
    Courtesy of FORD MOTOR CO.

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.

Remove the forward clutch piston.
1. Place the forward clutch cylinder with forward clutch piston facing down.
2. Install the center support on the forward clutch cylinder.
3. Apply air pressure to the left port of the center support.
  
  Fig 5: Removing Forward Clutch Piston
  Courtesy of FORD MOTOR CO.
Remove and discard the forward clutch piston seals.
1. Remove the forward clutch piston outer seal and inspect the forward clutch piston for cracks.
2. Remove forward clutch cushion spring.
  
  Fig 6: Removing Forward Clutch Piston Seals
  Courtesy of FORD MOTOR CO.
Inspect the forward clutch drum components.
- Inspect clutch plate serration for scores or burrs.
- Inspect fluid passages for obstructions. Clean out all passages.
- Inspect the friction clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surface. Install new parts that are deeply scored.
- Check clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.
- Check clutch hub thrust surfaces for scores and clutch hub splines for wear.
- Inspect for damage or wear to the clutch disc grooves and retaining ring grooves.
Inspect the remaining forward clutch drum components for damage or wear, install new components as necessary.
1. Inspect the forward clutch cylinder surfaces for scores or burrs. Install a new forward clutch cylinder if it is badly scored or damaged.
2. Inspect forward clutch piston for scores or burrs.
3. Make sure the check ball is free and clear of foreign material, has freedom of movement and is correctly seated.
  
  Fig 7: Inspecting Remaining Forward Clutch Drum Components For Damage Or Wear
  Courtesy of FORD MOTOR CO.
Inspect the needle bearing for damage. If the bearing is damaged, install a new drum assembly.

Fig 8: Inspecting Needle Bearing For Damage
Courtesy of FORD MOTOR CO.