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Overdrive/Direct Clutch Assembly: Assembly

  1. Install the direct clutch wave spring.
    2. Fig 1: Identifying direct Clutch Wave Spring
    GF0044203Courtesy of FORD MOTOR CO.
  2. Lubricate the direct clutch pack in clean automatic transmission fluid.
    3. Fig 2: Identifying Direct Clutch Pack
    GF0044204Courtesy of FORD MOTOR CO.
  3. Install the direct clutch assembly and pressure plate.
    4. Fig 3: Identifying Direct Clutch Assembly And Pressure Plate
    GF0044202Courtesy of FORD MOTOR CO.
  4. Install the direct clutch snap ring.
    5. Fig 4: Identifying Direct Clutch Snap Ring
    GF0044201Courtesy of FORD MOTOR CO.
  5. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
    6. Fig 5: Identifying Direct Clutch Piston Seals
    GF0044205Courtesy of FORD MOTOR CO.
  6. Install the direct clutch piston return spring.
    7. Fig 6: Identifying Direct Clutch Piston Return Spring
    GF0044199Courtesy of FORD MOTOR CO.
  7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
    8. Fig 7: Identifying Direct Clutch Piston
    GF0044198Courtesy of FORD MOTOR CO.
  8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
    9. Fig 8: Identifying Rear Direct Clutch Piston Seal
    GF0044197Courtesy of FORD MOTOR CO.
  9. Install the direct clutch cylinder.
    10. Fig 9: Identifying Direct Clutch Cylinder
    GF0044196Courtesy of FORD MOTOR CO.
    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 and Balance Piston Service Set 307-589/2 and the 2-6 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.
    11. Fig 10: Identifying Clutch Hub And Shaft Assembly
    GF0044194Courtesy of FORD MOTOR CO.
  11. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2 .
    12. Fig 11: Identifying Overdrive Clutch and Balance Piston Service Set
    GF0044195Courtesy of FORD MOTOR CO.
  12. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
    13. Fig 12: Identifying Overdrive Clutch Piston
    GF0044206Courtesy of FORD MOTOR CO.
  13. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
    14. Fig 13: Identifying Overdrive Clutch Piston Inner Seal
    GF0044207Courtesy 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 Overdrive Clutch and Balance Piston Service Set 307-589/1.
    15. Fig 14: Identifying Overdrive Clutch Piston
    GF0044208Courtesy of FORD MOTOR CO.
    NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.
  15. Install the overdrive clutch piston return spring.
    16. Fig 15: Identifying Overdrive Clutch Piston Return Spring
    GF0044188Courtesy of FORD MOTOR CO.
  16. Lubricate the seals on a new balance piston.
    17. Fig 16: Identifying Balance Piston
    GF0044209Courtesy of FORD MOTOR CO.
  17. Install the new balance piston and install the Overdrive Clutch and Balance Piston Service Set 307-589/1 and 2-6 Spring Compressor 307-584/2 on the balance piston.
    18. Fig 17: Identifying Overdrive Clutch and Balance Piston Service Set
    GF0044186Courtesy of FORD MOTOR CO.
  18. Using a press, compress the overdrive clutch piston return spring and install the snap ring.
    19. Fig 18: Identifying Overdrive Clutch Piston Return Spring
    GF0044185Courtesy of FORD MOTOR CO.
  19. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/1 and the 2-6 Spring Compressor 307-584/2 from the balance piston.
    20. Fig 19: Identifying Overdrive Clutch and Balance Piston Service Set
    GF0044186Courtesy of FORD MOTOR CO.
  20. Install the No. 2 rear sun gear thrust bearing.
    21. Fig 20: Identifying No. 2 Rear Sun Gear Thrust Bearing
    GF0044183Courtesy of FORD MOTOR CO.
  21. Install the overdrive clutch hub.
    22. Fig 21: Identifying Overdrive Clutch Hub
    GF0044210Courtesy of FORD MOTOR CO.
  22. Lubricate the overdrive clutch pack in clean automatic transmission fluid.
    23. Fig 22: Identifying Overdrive Clutch Pack
    GF0044211Courtesy of FORD MOTOR CO.
  23. Install the overdrive clutch pack assembly and the pressure plate.
    24. Fig 23: Identifying Overdrive Clutch Pack Assembly
    GF0044212Courtesy of FORD MOTOR CO.
  24. Install the overdrive clutch pack snap ring.
    25. Fig 24: Identifying Overdrive Clutch Pack Snap Ring
    GF0044213Courtesy 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. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.090 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.
    26. Fig 25: Identifying Overdrive/direct Clutch Assembly
    GF0044214Courtesy 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. The clearance should be between 0.98 mm (0.039 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.
    27. Fig 26: Identifying Dial Indicator Gauge
    GF0044215Courtesy of FORD MOTOR CO.
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