Direct Clutch Assembly: Reassembly

Using Seal Protector (T80L-77234-A), install inner seal on clutch drum hub with sealing lip facing down into drum. Lubricate seals and seal protector with petroleum jelly prior to installation. Ensure inner seal is positioned in groove. Install outer seal on piston with lip pointing away from spring posts.
Coat piston seals, clutch drum sealing area, and piston inner seal area with petroleum jelly. Install piston into clutch drum using Seal Protector (T80L-77254-A) to prevent damaging seals.
Position piston spring and retainer assembly in clutch drum. Compress assembly and install retaining snap ring. Install clutch pack into drum. Install pressure plate on top of clutch pack. Install clutch pack selective retaining ring.
Using a feeler gauge, measure clearance between clutch pack retaining ring and pressure plate with pressure plate held down. See DIRECT CLUTCH PLATE USAGE & CLEARANCE .
If clearance is not within specifications, selective snap rings are available in various sizes. See DIRECT CLUTCH SNAP RINGS . Install correct size snap ring and recheck clearance.
To check clutch for proper operation, use compressed air at 30 psi (2.1 kg/cm² ). See Fig 2 . Clutch should be heard and felt to apply smoothly and without leakage.

DIRECT CLUTCH PLATE USAGE & CLEARANCE

Engine Application

Steel Plates

Friction Plates

Clearance In. (mm)

3.8L SC

.060-.088 (1.5 3-2.23)

All Others ⁽¹⁾

.050-.067 (1.27-1.70)

⁽¹⁾	Some models equipped with 4.6L or 5.0L engines may have 6 steel plates and 6 friction plates with .060-.092" (1.53-2.34 mm) clearances.

DIRECT CLUTCH SNAP RINGS

Part No.

⁽¹⁾ Thickness

E0AZ7D483-A

.052" (1.32 mm)

E0AZ7D483-B

.066" (1.68 mm)

E0AZ7D483-C

.080" (2.03 mm)

E0AZ7D483-D

.094" (2.39 mm)

⁽¹⁾	Snap ring thicknesses have .002" (.05 mm) tolerance.

Fig 1: Exploded View of Direct Clutch Assembly

Courtesy of FORD MOTOR CO.

Fig 2: Checking Direct Clutch Operation

Courtesy of FORD MOTOR CO.