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Forward/Coast/Direct Clutches: Assembly

  1. Soak the internal spline clutch plates in clean automatic transmission fluid.
  2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.
    3. Fig 1: Installing Forward Clutch Piston Inner Seal On Forward/Coast/Direct Clutch Cylinder Assembly
    GF0024994Courtesy of FORD MOTOR CO.
  3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
    4. Fig 2: Forward Clutch Piston Outer Lip Seal
    GF0024997Courtesy of FORD MOTOR CO.
  4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
    5. Fig 3: Forward Clutch Piston Assembly
    GF0024993Courtesy of FORD MOTOR CO.
  5. Mark the center of 2 adjacent legs on the top of the cylinder.
    6. Fig 4: Marking Center Of 2 Adjacent Legs
    GF0024998Courtesy of FORD MOTOR CO.
  6. Find the center between the marks (45 degrees from either leg) and mark the cylinder.
    7. Fig 5: Marking Cylinder
    GF0024999Courtesy of FORD MOTOR CO.
  7. Install the coast clutch piston assembly onto the special tool.
    8. Fig 6: Installing Coast Clutch Piston Assembly Onto Special Tool
    GF0025000Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.
    9. Fig 7: Installing Coast Clutch Piston Into Forward Clutch Piston Assembly Using Special Tools
    GF0025001Courtesy of FORD MOTOR CO.
  9. Install the forward/coast clutch return spring assembly.
    10. Fig 8: Forward/Coast Clutch Return Spring Assembly
    GF0024992Courtesy of FORD MOTOR CO.
    WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.
  10. Install the forward/coast clutch return spring retaining ring.
    1. Using the special tool, compress the return spring.
    2. Install the forward/coast clutch retaining ring.
    3. Orient the gap between the piston legs.
    11. Fig 9: Forward/Coast Clutch Return Spring Retaining Ring & Special Tools
    GF0024985Courtesy of FORD MOTOR CO.
  11. Install the forward and coast clutch plates in the sequence shown.
    1. Coast clutch external spline clutch plates (steel)
    2. Coast clutch internal spline clutch plates (friction)
    3. Coast clutch pressure plate
    4. Forward clutch wave spring
    5. Forward clutch internal spline clutch plates (friction)
    6. Forward clutch external spline clutch plates (steel)
    7. Forward clutch pressure plate
    12. Fig 10: Identifying Forward & Coast Clutch Pressure Plates
    GF0025002Courtesy of FORD MOTOR CO.
  12. Install the forward clutch pressure plate retaining ring.
    • Center the select fit retaining ring on the 45 degree mark between the 2 adjacent legs.
    13. Fig 11: Locating Clutch Pressure Plate Retaining Ring
    GF0025003Courtesy of FORD MOTOR CO.
  13. Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring.
    • Take a second measurement on the opposite side.
    • Average the 2 measurements to get the clearance.
    • If the clearance is not within specification, select and install the correct thickness retaining ring to obtain the standard clearance.
    • Retaining ring sizes:
      • 1.43-1.53 mm (0.056-0.060 in).
      • 1.59-1.69 mm (0.062-0.066 in).
      • 1.75-1.85 mm (0.069-0.073 in).
      • 1.92-2.02 mm (0.075-0.079 in).
    14. Fig 12: Checking Clearance (With Specifications)
    GF0025004Courtesy of FORD MOTOR CO.
  14. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.
    15. Fig 13: Direct Clutch Piston Inner Lip Seal
    GF0025005Courtesy of FORD MOTOR CO.
  15. Install the direct clutch piston outer seal on the direct clutch piston assembly.
    16. Fig 14: Direct Clutch Piston Outer Seal
    GF0025006Courtesy of FORD MOTOR CO.
    NOTE: Position the lip seal facing down.
  16. Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
    17. Fig 15: Direct Clutch Piston Assembly
    GF0024987Courtesy of FORD MOTOR CO.
  17. Install the direct clutch return spring assembly.
    18. Fig 16: Direct Clutch Return Spring Assembly
    GF0024986Courtesy of FORD MOTOR CO.
    WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.
    CAUTION: Do not compress the direct clutch return springs completely.
  18. Install the direct clutch return spring retaining ring.
    1. Using the special tool, compress the direct clutch return springs.
    2. Install the direct clutch return spring retaining ring.
    19. Fig 17: Forward/Coast Clutch Return Spring Retaining Ring & Special Tools
    GF0024985Courtesy of FORD MOTOR CO.
    NOTE: Quantity of plates are model dependent.
  19. Install the direct clutch plates.
    1. Install the direct clutch external spline (steel) clutch plates.
    2. Install the direct clutch internal spline (friction) clutch plates.
    3. Install the direct clutch pressure plate.
    20. Fig 18: Identifying Clutch Pressure Plate
    GF0025007Courtesy of FORD MOTOR CO.
  20. Install the direct clutch pressure plate retaining ring.
    21. Fig 19: Direct Clutch Pressure Plate Retaining Ring
    GF0024983Courtesy of FORD MOTOR CO.
  21. Measure the direct clutch clearance as follows:
    • Install the special tool.
    • Zero the dial on the direct clutch pressure plate.
    • Pull the direct clutch pressure plate upward, and record the reading.
    22. Fig 20: Measuring Direct Clutch Clearance (With Specifications)
    GF0025008Courtesy of FORD MOTOR CO.
  22. Make a second measurement on the opposite side. Average the 2 measurements to get the clearance. If the clearance is not within the specification, select and install, using the special tool, the correct thickness direct clutch pressure plate retainer snap ring to obtain the standard clearance.
    • Retaining ring sizes:
      • 1.28-1.38 mm (0.050-0.054 in).
      • 1.39-1.49 mm (0.054-0.058 in).
      • 1.52-1.62 mm (0.059-0.063 in).
      • 1.65-1.75 mm (0.064-0.069 in).
    23. Fig 21: Inspecting Correct Thickness Direct Clutch Pressure Plate Retainer Snap Ring
    GF0025009Courtesy of FORD MOTOR CO.
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