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Home >> Lincoln >> 2003 >> Aviator RWD >> Repair and Diagnosis >> Transmission >> Automatic Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> Forward Clutch >> Material

Forward Clutch: Material

Fig 1: Materials
G01635314Courtesy of FORD MOTOR CO.
CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid for at least 30 minutes before assembly.
NOTE: If the seals on the forward clutch piston show any signs of damage, a new forward clutch piston must be installed.
NOTE: Inspect the clutch components for damage or wear. Install new components as necessary.
  1. Disassemble the components in the order indicated in the following illustration.
  2. To assemble, reverse the disassembly procedure.
    Fig 2: Disassembling Sequence Of Forward Clutch
    G01635315Courtesy of FORD MOTOR CO.

Item 5: Retaining Ring Disassembly Note 

    WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.
    CAUTION: Do not fully depress the special tool or damage to the spring retainer may occur.
    Fig 3: Removing Forward Clutch Piston Retaining Ring
    G01635316Courtesy of FORD MOTOR CO.
  1. Using the special tool, remove the forward clutch piston retaining ring.

Item 7: Forward Clutch Piston Disassembly Note 

    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.
  1. Remove the forward clutch piston.
    1. Place the forward clutch cylinder with forward clutch piston facing down.
    2. Install the center support on the forward clutch cylinder.
    3. Apply air pressure to the left port of the center support.
      Fig 4: Applying Air Pressure To Left Port
      G01635317Courtesy of FORD MOTOR CO.

Item 8: Forward Clutch Cylinder Assembly Note 

  1. Inspect the forward clutch drum assembly.
    1. Inspect the forward clutch cylinder surfaces for scores or burrs.
    2. Inspect forward clutch piston for scores or burrs.
    3. Verify the check ball is free to move in the piston.
      Fig 5: Inspecting Forward Clutch Drum Assembly
      G01635318Courtesy of FORD MOTOR CO.

Item 7: Forward Clutch Piston Inspection Note 

  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.

Item 7: Forward Clutch Piston Assembly Note 

    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.
    Fig 6: Installing Special Tool On Forward Clutch Piston
    G01635319Courtesy of FORD MOTOR CO.
  1. Install the special tool on the forward clutch piston.
    2. 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 7: Installing Forward Clutch Piston Assembly
    G01635320Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.

Item 5: Retaining Ring Assembly Note 

    CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
    Fig 8: Installing Forward Clutch Piston Spring Retaining Ring
    G01635321Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the forward clutch piston spring retaining ring.

Items 4 and 3: Forward Clutch Internal Splined Steel and External Splined Friction Plates Assembly Note 

    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 9: Installing Direct Clutch Disc Pack
    G01635322Courtesy of FORD MOTOR CO.
  1. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
  2. Install the steel clutch plates and friction clutch plates in an alternating order, starting with a steel clutch plate.
    Fig 10: Installing Steel Clutch Plates And Friction Clutch Plates
    G01635323Courtesy of FORD MOTOR CO.

Item 1: Retaining Ring Assembly Note 

    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.
  1. 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.
      Fig 11: Applying Air Pressure To Left Port Of Center Support
      G01635324Courtesy of FORD MOTOR CO.
  2. 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 12: Retaining Ring Chart
      G01635325Courtesy of FORD MOTOR CO.
      Fig 13: Checking Gap Between Forward Clutch Retaining Ring And Forward Clutch Pressure Plate
      G01635326Courtesy of FORD MOTOR CO.
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