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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 665 (Automatic Transmission - 4R100 - Excursion & F250-F550 Super Duty) >> Disassembly & Assembly Of Subassemblies >> Forward Clutch Assembly >> Assembly

Forward Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Soak the clutch plates for 15 minutes in clean automatic transmission fluid.
  1. Install the forward clutch piston inner seal.
    Fig 1: Installing Forward Clutch Piston Inner Seal
    G02775278Courtesy of FORD MOTOR CO.
  2. Inspect the forward clutch piston check ball.
    • Check for freedom of movement and correct seating.
    • Clean with a suitable solvent, if necessary.
    • Replace the forward clutch piston assembly, if necessary.
      Fig 2: Inspecting Forward Clutch Piston
      G02775279Courtesy of FORD MOTOR CO.
    3. NOTE: Make sure the seal lip is facing upward.
    Fig 3: Installing Forward Clutch Piston Outer Seal
    G02775280Courtesy of FORD MOTOR CO.
  3. Install the forward clutch piston outer seal.
  4. Using the special tool, install the forward clutch piston.
    Fig 4: Installing Forward Clutch Piston
    G02775281Courtesy of FORD MOTOR CO.
  5. Install the steel forward clutch piston apply ring into the forward clutch piston groove.
    Fig 5: Installing Steel Forward Clutch Piston
    G02775282Courtesy of FORD MOTOR CO.
    6. CAUTION: To ensure durability, the notch between the spring fingers must be positioned so that both ends of the forward clutch piston apply ring are visible.
  6. Install the forward clutch piston return spring.
    1. Install the forward clutch piston return spring, with the spring fingers against the forward clutch piston apply ring.
    2. Make sure the notch is positioned so that both ends of the forward clutch piston apply ring are visible.
      Fig 6: Installing Forward Clutch Piston Return Spring
      G02775283Courtesy of FORD MOTOR CO.
  7. Install the forward clutch piston return spring retaining ring. Make sure it is correctly seated in the groove.
    Fig 7: Installing Forward Clutch Piston Return Spring Retaining Ring
    G02775284Courtesy of FORD MOTOR CO.
    8. NOTE: Soak the clutch plates for 15 minutes in clean automatic transmission fluid.
  8. Install the forward clutch pressure plates.
    1. Install the bottom forward clutch pressure plate.
    2. Install the forward clutch pressure spring.
    3. Install the forward clutch pressure plates.
    4. Install the top forward clutch pressure plate.
      Fig 8: Installing Bottom Forward Clutch Pressure Plate
      G02775285Courtesy of FORD MOTOR CO.
  9. Install the selective forward clutch pressure plate retaining ring.
    Fig 9: Installing Selective Forward Clutch Pressure Plate Retaining Ring
    G02775286Courtesy of FORD MOTOR CO.
  10. Check the stack-up clearance.
    • Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart.
    • If the clearance is not to specification, install the correct selective forward clutch pressure plate retaining ring and recheck the clearance. Refer to the Forward Clutch Pack .
      Fig 10: Installing Correct Selective Forward Clutch Pressure Plate
      G02775287Courtesy of FORD MOTOR CO.
    11. NOTE: Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly.
    NOTE: The bearing large inner diameter radius must face inward.
    Fig 11: Installing Forward Clutch Needle Bearing
    G02775288Courtesy of FORD MOTOR CO.
  11. Install the No. 8B forward clutch needle bearing.
    12. NOTE: Stagger the interlocking opening on the seals 180 degrees apart.
    Fig 12: Installing Two New Cast Iron Forward Clutch Cylinder Seals In Grooves
    G02775289Courtesy of FORD MOTOR CO.
  12. Install the two new cast iron forward clutch cylinder seals in the grooves.
    13. NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.
    NOTE: The black side of the bearing must face upward.
    Fig 13: Installing Forward Clutch Thrust Bearing
    G02775290Courtesy of FORD MOTOR CO.
  13. Install the No. 9A forward clutch thrust bearing.
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