Direct 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.

Lightly lubricate the new pistons with petroleum jelly.
1. Direct clutch piston
2. Direct clutch return spring
3. Direct clutch balance piston
  
  Fig 1: Lubricating Pistons
  Courtesy of FORD MOTOR CO.
Install a new direct clutch piston.

Fig 2: Installing Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Install the direct clutch return spring and a new balance piston.

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

Fig 4: Installing Snap Ring
Courtesy of FORD MOTOR CO.

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: Installing Plates
  Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 6: Installing Snap Ring
Courtesy of FORD MOTOR CO.
Using a feeler gauge, measure the clearance between the snap ring and the pressure plate.

Fig 7: Measuring Clearance Between Snap Ring And Pressure Plate
Courtesy of FORD MOTOR CO.