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.

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 Forward Clutch Balance Piston
  Courtesy of FORD MOTOR CO.
Install the forward clutch piston.

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

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

Fig 4: Installing Snap Ring
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: Installing Forward Clutch Pack
  Courtesy of FORD MOTOR CO.
Install the forward clutch snap ring.

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

Fig 7: Measuring 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: Installing Forward Clutch Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the No. 7 thrust washer and two new seals.

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