LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2002 >> Explorer 4.0 K, RWD, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul Automatic Transmission >> Disassembly And Assembly Of Subassemblies >> Forward Clutch >> Assembly

Forward Clutch: Assembly

  1. Inspect the clutch components for damage or wear. Install new components as necessary.
    • Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
    • Inspect the clutch plates for damage.
    • Inspect the clutch springs.
    • Inspect the needle bearing and seal rings for damage.
    • Check clutch hub thrust surfaces for damage.
    • Check clutch plates for flatness and fit on the clutch hub serrations.
    2. NOTE: The special tool must be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.
  2. Install the special tool on the forward clutch piston.
    3. Fig 1: Installing Piston Seal Sizer On Forward Clutch Piston
    G01672313Courtesy of FORD MOTOR CO.
    CAUTION: Care must be taken to prevent damage to the seals.
    NOTE: Lubricate the forward clutch piston inner and outer seal with clean automatic transmission fluid.
  3. Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.
    4. Fig 2: Installing Forward Clutch Piston
    G01672314Courtesy of FORD MOTOR CO.
  4. Install the forward clutch piston spring assembly.
    5. Fig 3: Installing Forward Clutch Piston Spring Assembly
    G01672315Courtesy of FORD MOTOR CO.
    CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
  5. Using the special tool, install the forward clutch piston spring retaining ring.
    6. Fig 4: Installing Forward Clutch Piston Spring Retaining Ring
    G01672316Courtesy of FORD MOTOR CO.
    CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise.
    CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid for at least 30 minutes before assembly.
  6. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
    7. Fig 5: Identifying Forward Clutch Plate Installation Direction
    G01672317Courtesy of FORD MOTOR CO.
  7. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
    8. Fig 6: Installing Forward Clutch Plate Disc Pack
    G01672318Courtesy of FORD MOTOR CO.
    CAUTION: The retaining ring is a select fit.
  8. Install the original selective retaining ring.
    1. Install the forward clutch pressure plate.
    2. Install the original selective retaining ring.
    9. Fig 7: Installing Forward Clutch Pressure Plate & Retaining Ring
    G01672319Courtesy 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.
  9. 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.
    10. Fig 8: Air Checking Clutch Assembly
    G01672320Courtesy of FORD MOTOR CO.
  10. 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: Measuring Forward Clutch Pack Clearance
G01672321Courtesy of FORD MOTOR CO.
Fig 10: Forward Clutch Pack Retaining Ring Thickness Table
G01672322Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals