Forward Clutch: Reassembly

Lubricate and install inner and outer seals on piston with seal lips facing into clutch drum. Lubricate piston seals and drum sealing area with petroleum jelly. Install piston into drum using Seal Protector (T80L-77140-A) to prevent damaging seals.
Position return spring and retainer on piston. Compress return spring and install retaining snap ring. Install clutch pack into clutch drum starting with waved plate. Install clutch pack retaining snap ring.

Using a feeler gauge, measure clearance between retaining snap ring and pressure plate with pressure plate held down. Ensure clearance is .040-.071" (1.02-1.80 mm) for 3.8L EFI (4 clutches) engine and .050-.089" (1.27-2.26 mm) for all others (5 clutches).

NOTE: If vehicle is not available at time of repair, application can be identified by number of clutches. See FORWARD CLUTCH PLATE USAGE .

FORWARD CLUTCH PLATE USAGE

Application

Steel Plates

Friction Plates

3.8L EFI ⁽¹⁾

All Others ⁽¹⁾

⁽¹⁾	Plus one waved plate installed next to piston.

FORWARD & REVERSE CLUTCH SNAP RINGS

Part No.

⁽¹⁾ Thickness

C8AZ7D483-C

.062" (1.57 mm)

C7AZ7D483-A

.078" (1.98 mm)

C8AZ7D483-B

.090" (2.29 mm)

C8AZ7D483-A

.104" (2.64 mm)

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

If clearance is not within specification, selective snap rings are available in various sizes. See FORWARD & REVERSE CLUTCH SNAP RINGS . Install correct size snap ring and recheck clearance.
With reassembly completed, use compressed air and check forward clutch operation. Clutch should be heard and felt to apply smoothly and without leakage.

Fig 1: Exploded View of Forward Clutch Assembly

Courtesy of FORD MOTOR CO.