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Home >> Lincoln >> 2011 >> MKT Base, AWD >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Automatic Transmission - Automatic Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> Overdrive/Direct Clutch Assembly >> Assembly

Overdrive/Direct Clutch Assembly: Assembly

  1. Install the direct clutch wave spring.
    Fig 1: Locating Direct Clutch Wave Spring
    G07793489Courtesy of FORD MOTOR CO.
  2. Lubricate the direct clutch pack in clean transmission fluid.
    Fig 2: Identifying Direct Clutch Pack
    G07793490Courtesy of FORD MOTOR CO.
  3. Install the direct clutch assembly and pressure plate.
    Fig 3: Installing Direct Clutch Assembly And Pressure Plate
    G07793491Courtesy of FORD MOTOR CO.
  4. Install the direct clutch snap ring.
    Fig 4: Installing Direct Clutch Snap Ring
    G07793492Courtesy of FORD MOTOR CO.
  5. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
    Fig 5: Installing Direct Clutch Piston Seals
    G07793493Courtesy of FORD MOTOR CO.
  6. Install the direct clutch piston return spring.
    Fig 6: Installing Direct Clutch Piston Return Spring
    G07793494Courtesy of FORD MOTOR CO.
  7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
    Fig 7: Installing Direct Clutch Piston
    G07793495Courtesy of FORD MOTOR CO.
  8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
    Fig 8: Installing Rear Direct Clutch Piston Seal
    G07793496Courtesy of FORD MOTOR CO.
  9. Install the direct clutch cylinder.
    Fig 9: Installing Direct Clutch Cylinder
    G07793497Courtesy of FORD MOTOR CO.
    10. NOTE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
    NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.
  10. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring and install the snap ring.
    1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.
    2. Install the snap ring.
      Fig 10: Installing Snap Ring
      G07793498Courtesy of FORD MOTOR CO.
  11. Remove the Overdrive Clutch, Balance Piston Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2.
    Fig 11: Removing Overdrive Clutch, Balance Piston, Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G07793499Courtesy of FORD MOTOR CO.
  12. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
    Fig 12: Installing Seals On Overdrive Clutch Piston
    G07793500Courtesy of FORD MOTOR CO.
  13. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
    Fig 13: Locating Overdrive Clutch Piston Inner Seal
    G07793501Courtesy of FORD MOTOR CO.
  14. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1.
    Fig 14: Pushing Overdrive Clutch Piston In Cylinder
    G07793502Courtesy of FORD MOTOR CO.
    15. NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.
    Fig 15: Locating Overdrive Piston Return Spring
    G07793503Courtesy of FORD MOTOR CO.
  15. Install the overdrive clutch piston return spring.
  16. Lubricate the seals on a new balance piston with petroleum jelly.
    Fig 16: Locating Seals On Balance Piston
    G07793504Courtesy of FORD MOTOR CO.
  17. Install the new balance piston and install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
    Fig 17: Installing Overdrive Clutch, Balance Piston, Direct Clutch Compressor Set 307-589/1 And Forward/Intermediate Spring Compressor
    G07793505Courtesy of FORD MOTOR CO.
  18. Using a press, compress the overdrive clutch piston return spring and install the snap ring.
    Fig 18: Locating Balance Piston Snap Ring
    G07793506Courtesy of FORD MOTOR CO.
  19. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and the Forward/Intermediate Spring Compressor 307-584/2 from the balance piston.
    Fig 19: Removing Overdrive Clutch, Balance Piston, Direct Clutch Compressor Set 307-589/1 And Forward/Intermediate Spring Compressor
    G07793507Courtesy of FORD MOTOR CO.
  20. Install the No. 2 rear sun gear thrust bearing.
    Fig 20: Removing No. 2 Rear Sun Gear Thrust Bearing
    G07793508Courtesy of FORD MOTOR CO.
  21. Install the overdrive clutch hub.
    Fig 21: Installing Overdrive Clutch Hub
    G07793509Courtesy of FORD MOTOR CO.
  22. Lubricate the overdrive clutch pack in clean transmission fluid.
    Fig 22: Identifying Overdrive Clutch Pack
    G07793510Courtesy of FORD MOTOR CO.
  23. Install the overdrive clutch pack assembly and the pressure plate.
    Fig 23: Locating Overdrive Clutch Pack Assembly
    G07793511Courtesy of FORD MOTOR CO.
  24. Install the overdrive clutch pack snap ring.
    Fig 24: Locating Overdrive Clutch Pack Snap Ring
    G07793512Courtesy of FORD MOTOR CO.
  25. Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator Gauge with Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.089 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
    Fig 25: Recording Clutch Pack Clearance On Dial Indicator
    G07793513Courtesy of FORD MOTOR CO.
  26. Position the Dial Indicator Gauge with Holding Fixture 100-002 on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 0.98 mm (0.038 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.
    Fig 26: Recording Clutch Pack Clearance On Dial Indicator
    G07793514Courtesy of FORD MOTOR CO.
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