Direct Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Lightly lubricate the new pistons with petroleum jelly.
1. Direct clutch piston.
2. Direct clutch return spring.
3. Direct clutch balance piston.

Fig 1: Direct Clutch Piston, Return Spring, And Balance Piston

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Install a new direct clutch piston.

Fig 2: Locating Direct Clutch Piston

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Install the direct clutch return spring and a new balance piston.

Fig 3: Locating Clutch Balance Piston And Return Spring

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Using the special tools, install the snap ring.

Fig 4: Identifying Snap Ring With Special Tools

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NOTE: The direct clutch plates are installed in an alternating sequence, starting with an externally splined steel plate, then an internally splined friction plate, with the pressure plate on the top just under the snap ring.

Install the plates.
1. Externally splined steel plates.
2. Internally splined friction plates.
3. Pressure plate.

Fig 5: Externally Splined Steel Plates, Internally Splined Friction Plates, And Pressure Plate - Direct Clutch

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Install the snap ring.

Fig 6: Locating Snap Ring

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Using a feeler gauge, measure the clearance between the snap ring and the pressure plate.

Fig 7: Checking Snap Ring And Pressure Plate Clearance With Specifications

Courtesy of FORD MOTOR CO.