Direct Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 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: Identifying Direct Clutch Piston, Direct Clutch Return Spring And Direct Clutch Balance Piston
  Courtesy of FORD MOTOR CO.
Install a new direct clutch piston.

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

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

Fig 4: Identifying Snap Ring With Special Tools
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: Identifying Externally Splined Steel Plates, Internally Splined Friction Plates And Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the snap ring.

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

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