Output Shaft and Direct Clutch Cylinder: Assembly

WARNING: This page is about a different car, the 2003 Mercury Marauder, 2003 Mercury Grand Marquis, and 2003 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly.

Fig 1: Installing Inner Piston Seal

Courtesy of FORD MOTOR CO.

Using the special tool, install the inner piston seal.
- Install the seal with sealing lip facing down.
Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder.

Fig 2: Installing Clutch Piston Outer Seal
Courtesy of FORD MOTOR CO.

NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.

Fig 3: Installing Direct Clutch Piston

Courtesy of FORD MOTOR CO.

Using the special tool, install the direct clutch piston.
Install the piston return spring and retainer assembly.
Using the special tool, compress the piston return spring and install the retaining ring.

Fig 4: Compressing Piston Return Spring And Install Retaining Ring
Courtesy of FORD MOTOR CO.

NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid for 15 minutes.

Fig 5: Installing Clutch Pack Retaining Ring

Courtesy of FORD MOTOR CO.

Install the clutch pack retaining ring.
1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
2. Install the clutch pack retaining ring.
Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate.
- If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.
  
  Fig 6: Selective Retaining Ring Specification
  Courtesy of FORD MOTOR CO.
Fig 7: Checking Clearance Between Clutch Pack Selective Retaining Ring And Pressure Plate Retaining Ring
Courtesy of FORD MOTOR CO.
Install the direct clutch hub.
1. Install the No.7 direct clutch inner bearing support.
2. Install the direct clutch hub.
Fig 8: Installing Direct Clutch Hub
Courtesy of FORD MOTOR CO.

NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.

CAUTION: Make sure the seals are lapped correctly. Internal damage may occur.

Fig 9: Installing Direct Clutch Seal Rings

Courtesy of FORD MOTOR CO.

Install the two direct clutch seal rings.
Install the output shaft hub.
- Position the output shaft hub.
- Install the retaining ring.
Fig 10: Installing Output Shaft Hub
Courtesy of FORD MOTOR CO.
Install the three output shaft seal rings.

Fig 11: Installing Output Shaft Seal Rings
Courtesy of FORD MOTOR CO.
Install the No. 8 needle bearing on the direct clutch cylinder.

Fig 12: Installing Needle Bearing On Direct Clutch Cylinder
Courtesy of FORD MOTOR CO.

NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.

Fig 13: Assembling Direct Clutch On Output Shaft

Courtesy of FORD MOTOR CO.

Assemble the direct clutch on the output shaft.

CAUTION: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear.

Fig 14: Installing Ring Gear On Output Shaft

Courtesy of FORD MOTOR CO.

Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.