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Home >> Mercury >> 2001 >> Cougar Base, 2.5 L, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle >> Disassembly And Assembly Of Subassemblies >> Forward/Coast/Direct Clutches >> Assembly

Forward/Coast/Direct Clutches: Assembly

  1. Soak the internal spline clutch plates in clean Motorcraft MERCON® Multi-purpose automatic transmission fluid or equivalent meeting MERCON® specification for 30 minutes before assembly.
  2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.
    Fig 1: Installing Forward Clutch Piston Inner Seal
    G02164611
  3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
    Fig 2: Installing Forward Clutch Piston Outer Lip Seal
    G02164612
  4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
    Fig 3: Installing Forward Clutch Piston Assembly
    G02164613
    5. NOTE: The select fit retaining ring must be centered between two adjacent legs.
    Fig 4: Marking Center Of 2 Adjacent Legs On Top Of Cylinder
    G02164614
  5. Using a felt tip marker (do not use a paint pen) mark the center of two adjacent legs on the top of the cylinder.
  6. Using a felt tip marker (do not use a paint pen) mark the cylinder at the center point between the marks on the two adjacent legs.
    Fig 5: Marking Cylinder At Center Point Between Marks On 2 Adjacent Legs
    G02164615
  7. Install the coast clutch piston assembly onto the special tool.
    Fig 6: Installing Coast Clutch Piston Assembly Onto Special Tool
    G02164616
  8. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.
    Fig 7: Installing Coast Clutch Piston Into Forward Clutch Piston Assembly
    G02164617
  9. Install the forward/coast clutch return spring assembly.
    Fig 8: Installing Forward/Coast Clutch Return Spring Assembly
    G02164618
    10. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.
    Fig 9: Aligning Gap Between Piston Legs
    G02164619
  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.
    • align the gap between the piston legs.
  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.
    Fig 10: Identifying Forward & Coast Clutch Plates
    G02164620
  12. Position the select fit retaining ring on the center mark between the two adjacent legs.
    Fig 11: Positioning Select Fit Retaining Ring On Center Mark
    G02164621
  13. Measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring with a feeler gauge.
    • Take a second measurement on the opposite side.
    • Average the two measurements to get the clearance.
    • If the clearance is not within specification, select and install the proper thickness retaining ring to obtain the standard clearance.
    • Retaining ring sizes:
    Fig 12: Measure Clearance Between Forward Clutch Pressure Plate & Forward Clutch Pressure Plate
    G02164622
    • 1.43-1.53 mm (0.056-0.060 inch)
    • 1.59-1.69 mm (0.063-0.067 inch)
    • 1.75-1.85 mm (0.069-0.073 inch)
    • 1.92-2.02 mm (0.076-0.080 inch)
  14. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.
    Fig 13: Installing Direct Clutch Piston Inner Lip Seal
    G02164623
  15. Install the direct clutch piston outer seal on the direct clutch piston assembly.
    Fig 14: Install Direct Clutch Piston Outer Seal
    G02164624
    16. NOTE: Position the lip seal facing down.
    Fig 15: Installing Direct Clutch Piston Assembly
    G02164625
  16. Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
  17. Install the direct clutch return spring assembly.
    Fig 16: Installing Direct Clutch Return Spring Assembly
    G02164626
    18. 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 compress the direct clutch return springs completely.
    Fig 17: Installing Direct Clutch Return Spring Retaining Ring
    G02164627
  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. 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.
    Fig 18: Installing Direct Clutch Plates
    G02164628
  20. Install the direct clutch pressure plate retaining ring.
    Fig 19: Installing Direct Clutch Pressure Plate Retaining Ring
    G02164629
  21. Measure the direct clutch clearance as follows for four plate clutch:
    • Install the special tool.
    • Zero the dial on the direct clutch pressure plate.
    • Pull the direct clutch pressure plate upward, and record the reading.
    Fig 20: Measuring Direct Clutch Clearance
    G02164630
  22. Make a second measurement on the opposite side. Average the two 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 inch)
    • 1.39-1.49 mm (0.055-0.059 inch)
    • 1.52-1.62 mm (0.060.063 inch)
    • 1.65-1.75 mm (0.065-0.069 inch)
    Fig 21: Determining Correct Thickness Direct Clutch Pressure Plate Retainer Snap Ring
    G02164631
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