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Home >> Lincoln >> 2001 >> LS 3.9 A >> Repair and Diagnosis >> Transmission >> Transmission Control Systems >> Automatic Transmission >> Disassembly & Assembly Of Subassemblies >> Forward Clutch-Bonded Piston >> Assembly

Forward Clutch-Bonded Piston: 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 needs to be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.
    Fig 1: Identifying Bonded Piston Seal Sizer
    G02143757
  2. Install the special tool on the forward clutch piston.
    3. 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.
    Fig 2: Identifying Piston Seal Protector
    G02143758
  3. Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.
  4. Install the forward clutch piston spring assembly.
    Fig 3: Identifying Forward Clutch Piston Spring Assembly
    G02143759
    5. CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
    Fig 4: Identifying Forward Clutch Piston Spring Retaining Ring
    G02143760
  5. Using the special tool, install the forward clutch piston spring retaining ring.
    6. 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.
    Fig 5: Install Direct Clutch Disc Pack In Counterclockwise Direction
    G02143761
  6. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
  7. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
    Fig 6: Identifying Forward Clutch Pack
    G02143762
    8. CAUTION: The retaining ring is a select fit.
    Fig 7: Identifying Forward Clutch Pressure Plate & Selective Retaining Ring
    G02143763
  8. Install the original selective retaining ring.
    1. Install the forward clutch pressure plate.
    2. Install the original selective retaining ring.
    9. 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.
      4. Fig 8: Identifying Forward Clutch Cylinder, Center Support & Left Port Of Center Support
      G02143764
  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 Gap Between Forward Clutch Retaining Ring & Forward Clutch Pressure Plate
    G02143765
    Fig 10: Identifying Retaining Ring Thicknesses
    G02143766
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