Forward And Reverse Clutch Drum Assembly: Assembly

CAUTION: Composition clutch plates and synthetic seals should not be cleaned in a vapor degreaser or with any type of detergent cleaner. To clean these parts, wipe them off with a lint free cloth. New clutch plates or bands should be soaked in Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON for two hours before being assembled.

NOTE: Clean the components with a suitable solvent and use compressed air to dry all parts and clean fluid passages. Inspect all clutches for damage and wear. Check each clutch piston and drum seal area for burrs or damage. Check for worn or broken springs.

NOTE: Clutch clearances are adjusted by the selection of snap ring thickness. If the clearance is not within specifications, adjust as necessary.

Inspect the reverse clutch piston.
1. Verify that there is air flow when applying compressed air through the fluid hole on the return spring side. Apply a maximum air pressure of 390 kPa (57 psi).
2. Verify that there is no air leakage when applying compressed air through the fluid hole opposite the return spring. Apply a maximum air pressure of 390 kPa (57 psi).
Fig 1: Inspecting Reverse Clutch Piston
Courtesy of FORD MOTOR CO.
Apply Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the inner and outer faces of the new reverse clutch piston large seal and the reverse clutch piston small seal. Install the inner and outer seal on the reverse clutch piston.
1. Measure the reverse clutch piston large seal inner diameter, replace if needed.
2. Measure the reverse clutch piston small seal inner diameter, replace if needed.
Fig 2: Measuring Reverse Clutch Piston Small Seal Inner Diameter
Courtesy of FORD MOTOR CO.
Attach Low Reverse Holding Piston Seal Protector to the reverse clutch piston to install the reverse clutch piston into the reverse clutch drum.
1. Install the reverse clutch piston and Low Reverse Holding Piston Seal Protector into the reverse clutch drum.
2. Seat the reverse clutch piston by pushing evenly around the circumference of the piston. If necessary, use a screwdriver to seat the reverse clutch piston. Remove Low Reverse Holding Seal Protector.
Fig 3: Installing Reverse Clutch Piston Into Reverse Clutch Drum
Courtesy of FORD MOTOR CO.
Install the reverse clutch pressure spring.
- The reverse clutch pressure spring tabs face away from the reverse clutch piston.
Fig 4: Installing Reverse Clutch Pressure Spring
Courtesy of FORD MOTOR CO.
Install the reverse clutch spacer. The reverse clutch spacer step faces upward.

Fig 5: Installing Reverse Clutch Spacer
Courtesy of FORD MOTOR CO.
Install the reverse clutch piston snap ring.
- Install the reverse clutch piston snap ring halfway down the reverse clutch drum.
Fig 6: Installing Reverse Clutch Piston Snap Ring
Courtesy of FORD MOTOR CO.
Use Return Spring Compressor to compress the reverse clutch pressure spring and the reverse clutch spacer.
- Install the reverse clutch snap ring with a screwdriver.
Fig 7: Installing Reverse Clutch Snap Ring With A Screwdriver
Courtesy of FORD MOTOR CO.
Install the reverse clutch piston spring.

Fig 8: Installing Reverse Clutch Piston Spring
Courtesy of FORD MOTOR CO.
Install the reverse clutch disc pack.
- The installation order is steel-friction-steel-friction.
Fig 9: Installing Reverse Clutch Disc Pack
Courtesy of FORD MOTOR CO.
Install the reverse clutch pressure plate.

Fig 10: Installing Reverse Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
Install the reverse clutch snap ring.

Fig 11: Installing Reverse Clutch Snap Ring
Courtesy of FORD MOTOR CO.
With the reverse clutch assembled, check the reverse clutch disc pack clearance.
- Use a feeler gauge to measure the clearance between the reverse clutch pressure plate and the reverse clutch pressure plate snap ring. If the clearance is not within the specification, adjust it by selecting the proper snap ring.
Snap Ring Sizes

Fig 12: Snap Ring Sizes Table
Courtesy of FORD MOTOR CO.

Fig 13: Checking Reverse Clutch Disc Pack Clearance
Courtesy of FORD MOTOR CO.
Inspect the coasting clutch piston.
- Verify that there is air flow when applying compressed air through the fluid hole on the return spring side. Apply a maximum air pressure of 390 kPa (57 psi).
- Verify that there is no air leakage when applying compressed air through the fluid hole opposite the return spring. Apply a maximum air pressure of 390 kPa (57 psi).
Fig 14: Inspecting Coasting Clutch Piston
Courtesy of FORD MOTOR CO.
Apply the specified amount of Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the inner and outer faces of the new coasting clutch piston outer seal and the coasting clutch piston inner seal. Install the inner and outer seal on the coasting clutch drum.
1. Measure the coasting clutch piston inner seal inner diameter.
2. Measure the coasting clutch piston outer seal inner diameter.
Fig 15: Measuring Coasting Clutch Piston Outer Seal Inner Diameter
Courtesy of FORD MOTOR CO.
Install the coasting clutch drum and the coasting clutch drum large seal, into the reverse clutch drum.
- Align the coasting clutch drum with the reverse clutch drum.
Fig 16: Aligning Coasting Clutch Drum With Reverse Clutch Drum
Courtesy of FORD MOTOR CO.
Apply the specified amount of Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the inner and outer faces of the new coasting clutch piston outer seal and the coasting clutch piston inner seal. Install the inner and outer seal on the coasting clutch piston.
1. Measure the coasting clutch piston inner seal inner diameter, then install.
2. Install the coasting clutch piston inner seal.
Fig 17: Measuring Coasting Clutch Piston Inner Seal Inner Diameter
Courtesy of FORD MOTOR CO.
Install the coasting clutch piston into the coasting clutch drum.
1. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the coasting clutch drum.
2. Seat the coasting clutch piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.
Fig 18: Installing Coasting Clutch Piston Into Coasting Clutch Drum
Courtesy of FORD MOTOR CO.
Install the coasting clutch return spring and retainer.

Fig 19: Installing Coasting Clutch Return Spring And Retainer
Courtesy of FORD MOTOR CO.
Install Clutch Spring Compressor and compress the coasting clutch return spring and retainer. Install the coasting clutch return spring snap ring.
1. Install Clutch Spring Compressor and compress the coasting clutch spring and retainer enough to install the coasting clutch return spring snap ring.
2. Install the coasting clutch return spring snap ring.
Fig 20: Installing Coasting Clutch Return Spring Snap Ring
Courtesy of FORD MOTOR CO.
Install the coasting clutch piston spring.

Fig 21: Installing Coasting Clutch Piston Spring
Courtesy of FORD MOTOR CO.
Install the coasting clutch disc pack.
- The installation order is steel-friction-steel-friction.
Fig 22: Installing Coasting Clutch Disc Pack
Courtesy of FORD MOTOR CO.
Install the coasting clutch pressure plate.

Fig 23: Installing Coasting Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
Install the coasting clutch pressure plate snap ring.

Fig 24: Installing Coasting Clutch Pressure Plate Snap Ring
Courtesy of FORD MOTOR CO.
With the coasting clutch assembled, check the coasting clutch disc pack clearance.
- Use a feeler gauge to measure between the coasting clutch pressure plate and the coasting clutch pressure plate snap ring. The clearance should be 1.0-1.2 mm (0.039-0.047 in). If the clearance is not within the specification, adjust it by selecting the proper snap ring.
Snap Ring Sizes

Fig 25: Snap Ring Sizes Table
Courtesy of FORD MOTOR CO.

Fig 26: Checking Coasting Clutch Disc Pack Clearance
Courtesy of FORD MOTOR CO.
Install the forward clutch spring.

Fig 27: Installing Forward Clutch Spring
Courtesy of FORD MOTOR CO.
Install the forward clutch disc pack.
- The installation order is steel-friction-steel-friction-steel-friction.
Fig 28: Installing Forward Clutch Disc Pack
Courtesy of FORD MOTOR CO.
Install the forward clutch pressure plate.

Fig 29: Installing Forward Clutch Pressure Plate
Courtesy of FORD MOTOR CO.
Install the forward clutch pressure plate snap ring.

Fig 30: Installing Forward Clutch Pressure Plate Snap Ring
Courtesy of FORD MOTOR CO.
With the forward clutch assembled, check the forward clutch disc pack clearance.
- Use a feeler gauge to measure between the forward clutch pressure plate and the forward clutch pressure plate snap ring. The clearance should be 1.0-1.2 mm (0.039-0.047 in). If the clearance is not within the specification, adjust it by selecting the proper snap ring.
Snap Ring Sizes

Fig 31: Snap Ring Sizes Table
Courtesy of FORD MOTOR CO.

Fig 32: Checking Forward Clutch Disc Pack Clearance
Courtesy of FORD MOTOR CO.

NOTE: To check the clutch operation, apply a maximum air pressure of 390 kPa (57 psi).

Fig 33: Checking Clutch Operation

Courtesy of FORD MOTOR CO.

Check each clutch operation after assembly.
1. Position the clutch assembly onto the pump.
2. Check the forward clutch operation by applying compressed air to the forward clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.
3. Check the reverse clutch operation by applying compressed air to the reverse clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.
4. Check the coasting clutch operation by applying compressed air to the coasting clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.