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Intermediate Brake & Direct Clutch Drum Assembly: Disassembly

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The retaining ring is a select fit. See assembly procedure if installation of new ring or clutch pack is required.
    Fig 1: Removing Direct Clutch Retaining Ring & Direct Clutch Pressure Plate
    G02152861Courtesy of FORD MOTOR CO.
  1. Remove the direct clutch retaining ring and the direct clutch pressure plate.
    1. Remove the direct clutch retaining ring.
    2. Remove the direct clutch pressure plate.
    2. CAUTION: Clutch plates are directional. Note the direction of the grooves for installation.
    CAUTION: If new clutch plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.
    Fig 2: Removing Direct Clutch Disc Pack
    G02152862Courtesy of FORD MOTOR CO.
  2. Remove the direct clutch disc pack.
    • Inspect and install new steel and friction plates if worn, damaged, or overheated.
    • Measure and record the thickness of the steel plates for assembly.
    3. WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.
    CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.
    Fig 3: Removing Direct Clutch Piston Retaining Ring
    G02152863Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the direct clutch piston retaining ring.
  4. Relieve the direct clutch spring tension and remove the special tool.
  5. Remove the direct clutch piston spring retainer and the 20 direct clutch piston springs.
    1. Lift the direct clutch piston spring retainer off the direct clutch piston springs.
    2. Remove the direct clutch piston springs.
    Fig 4: Removing Direct Clutch Piston Spring Retainer & Direct Clutch Piston Springs
    G02152864Courtesy of FORD MOTOR CO.
    6. WARNING: Do not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.
    Fig 5: Removing Direct Clutch Piston
    G02152865Courtesy of FORD MOTOR CO.
  6. Using compressed air, remove the direct clutch piston from the intermediate brake and direct clutch drum.
    • Apply air pressure to the hole in the drum while blocking the other with a finger.
  7. Remove the direct clutch piston inner and outer seal.
    1. Remove the direct clutch piston inner seal.
    2. Remove the direct clutch piston outer seal.
    Fig 6: Removing Direct Clutch Piston Inner & Outer Seal
    G02152866Courtesy of FORD MOTOR CO.
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