Direct Clutch Drum Assembly: Assembly

NOTE: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

NOTE: Use new seals to help prevent seal failures.

Install the new direct clutch piston inner seal and the direct clutch piston outer seal.

Fig 1: Locating Direct Clutch Piston Inner Seal And Direct Clutch Piston Outer Seal

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NOTE: Lubricate the direct clutch piston inner and outer seals with automatic transmission fluid.

Install the direct clutch piston into the Piston Seal Sizer.

Fig 2: Identifying Special Tool (307-336)

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Inspect the clutch components for damage or wear. Install new components as necessary.
- Inspect the drum surface for damage.
- Inspect the clutch piston bore and piston.
- 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.
- Verify the check ball is free to move.

Fig 3: Locating Check Ball

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Carefully remove the direct clutch piston from the Piston Seal Sizer.

Fig 4: Identifying Special Tool (307-336)

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NOTE: Care must be taken to prevent damage to the seals during installation.

Using the Piston Seal Protector, install the direct clutch piston.
- Lubricate the seals with transmission fluid before installing.

Fig 5: Installing Direct Clutch Piston Using Special Tool (307-049)

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Install the direct clutch piston springs and the retainer.

Fig 6: Locating Direct Clutch Piston Springs And Retainer

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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.

NOTE: Do not fully compress the Clutch Spring Compressor or damage to the spring retainer may occur.

Using the Clutch Spring Compressor, install the direct clutch piston retaining ring.

Fig 7: Identifying Special Tool (307-015) And Direct Clutch Piston Retaining Ring

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Relieve the direct clutch spring tension and remove the Clutch Spring Compressor.

NOTE: The direct clutch friction plates are directional and must be installed with grooves pointing clockwise (ID to OD) and the word TOP facing up, otherwise transmission damage can occur.

NOTE: If new plates are used, they should be soaked in transmission fluid before assembly, or damage to the plates may occur.

When installing friction plates, the word TOP should face up. If reusing plates, grooves must be installed clockwise. Install the direct clutch disc pack.

Fig 8: Installing Grooves Clockwise & Word TOP Should Face Up

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Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.

Fig 9: Identifying Direct Clutch Disc Pack

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NOTE: The retaining ring is a select fit.

Install the direct clutch pressure plate using the original direct clutch retaining ring.

Fig 10: Identifying Direct Clutch Pressure Plate And Direct Clutch Retaining Ring

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WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 psi) and always wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to follow this instruction may result in serious personal injury.

NOTE: The direct clutch piston must apply with air pressure and release when air is removed.

Air check the assembly.
- Apply air pressure to the hole in the drum while blocking the other hole.

Fig 11: Locating Drum Air Pressure Apply Hole

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Push down on the direct clutch disc pack and check the gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.

If the specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.

DIRECT CLUTCH

Part Number	Thickness		Diameter
Part Number	mm	Inch	mm	Inch
E860126-S	1.37	0.0539	130.1	5.122
E860127-S	1.73	0.0681	130.1	5.122
E860128-S	2.08	0.0819	130.1	5.122
E860129-S	2.44	0.0961	130.1	5.122

Fig 12: Checking Gap Between Direct Clutch Retaining Ring And Direct Clutch Pressure Plate (With Specifications)

Courtesy of FORD MOTOR CO.