Forward Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Lightly lubricate the new pistons and seals with petroleum jelly.
1. Forward clutch balance piston
2. Forward clutch balance piston return spring
3. Forward clutch piston
  
  Fig 1: Identifying Clutch Balance Piston Return Spring And Piston
  Courtesy of FORD MOTOR CO.
Install the forward clutch piston.

Fig 2: Locating Forward Clutch Piston
Courtesy of FORD MOTOR CO.
Install the forward clutch balance piston return spring and balance piston.

Fig 3: Locating Forward Clutch Balance Piston Return Spring
Courtesy of FORD MOTOR CO.
Using the special tools, install the snap ring.

Fig 4: Identifying Snap Ring With Special Tools
Courtesy of FORD MOTOR CO.

NOTE: Inspect the forward clutch plates for damage. If any damage is found, install new plates.

Install the forward clutch pack.
1. Cushion spring
2. Externally splined steel plates
3. Internally splined friction plates
4. Forward clutch pressure plate
  
  Fig 5: Identifying Forward Clutch Pack
  Courtesy of FORD MOTOR CO.
Install the forward clutch snap ring.

Fig 6: Locating Snap Ring And Forward Clutch Plates
Courtesy of FORD MOTOR CO.
Using a feeler gauge, measure the clearance between the snap ring and the pressure plate in 3 different locations.

Fig 7: Identifying Clearance Between Snap Ring And Pressure Plate
Courtesy of FORD MOTOR CO.
Install the No. 8 forward clutch thrust bearing, blue side up.

Fig 8: Identifying Forward Clutch Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the No. 7 thrust washer and 2 new seals.

Fig 9: Identifying Seals And Thrust Washer
Courtesy of FORD MOTOR CO.