Direct Clutch Assembly: Reassembly
- Install inner and outer seals in intermediate brake drum with seal lips facing down into drum. Ensure piston check ball moves freely. Install piston into drum. Ensure piston rotates freely in intermediate brake drum.
- Install return spring assembly with protrusions properly engaged with lugs on clutch piston. Use spring compressor and compress springs. Install retaining ring. Install clutch plates, first using a steel plate and then a friction plate. Install pressure plate and secure pack with selective retaining ring.
- Using a feeler gauge, check clearance between selective retaining ring and pressure plate. Ensure clearance is .045-.081" (1.14-2.06 mm). If clearance is not within specification, install correct selective retaining ring. Selective retaining rings are available in thicknesses of .056-.060" (1.42-1.52 mm), .065-.069" (1.65-1.75 mm), .074-.078" (1.88-1.98 mm) and .083-.087" (2.11-2.21 mm).
- Install correct selective retaining ring and recheck clearance. Apply a coat of petroleum jelly to No. 7 thrust washer and install onto intermediate brake drum. See Fig 1. Ensure tabs of No. 7 thrust washer are aligned with notches in intermediate brake drum.
- Install intermediate one-way clutch end cap, one-way clutch assembly, and bottom end cap into outer race. Lip on one-way clutch faces upward. Install outer race and one-way clutch assembly onto inner race to ensure race turns counterclockwise. Apply a coat of petroleum jelly to thrust washer No. 8A and install onto intermediate brake drum face. See Fig 1. Ensure tabs on thrust washer No. 8A align with notches in drum.
Courtesy of FORD MOTOR CO.