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Forward Clutch: Assembly

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air.
    2. NOTE: This step only needs to be carried out if the bearing was removed.
    Fig 1: View Of Forward Clutch Outer Race
    G02152893Courtesy of FORD MOTOR CO.
  2. Clean and lubricate the outer surface with clean transmission fluid.
    3. NOTE: This step only needs to be carried out if the bearing was removed.
    NOTE: The rectangular hole in the inside of the forward clutch bearing must face up (away from the forward clutch drum).
    Fig 2: Installing Forward Clutch Bearing With Rectangular Hole Facing Up
    G02152894Courtesy of FORD MOTOR CO.
  3. Install the forward clutch bearing with the rectangular hole facing up.
    4. NOTE: This step only needs to be carried out if the bearing was removed.
    Fig 3: Installing Forward Clutch Bearing
    G02152895Courtesy of FORD MOTOR CO.
  4. Using the special tools, install the forward clutch bearing.
    5. NOTE: This step only needs to be carried out if the bearing was removed.
    Fig 4: Inspecting That Bearing Is Correctly Seated On Drum
    G02152896Courtesy of FORD MOTOR CO.
  5. Inspect that the bearing is correctly seated on the drum. Inspect the top portion of the drum, that it was not damaged, and the bearing rotates freely.
    6. CAUTION: If there is evidence of clutch plate burning, install a new forward clutch cushion spring.
    Fig 5: Installing Forward Clutch Piston Seals
    G02152897Courtesy of FORD MOTOR CO.
  6. Install new forward clutch piston seals.
    1. Install the forward clutch piston outer seal.
    2. Install forward clutch cushion spring.
    3. Install the forward clutch piston inner seal.
    7. NOTE: Lubricate the forward clutch piston inner and outer seal with clean MERCON® V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON® V specification.
    Fig 6: Installing Lip Seal Protector Tools On Forward Clutch Piston
    G02152898Courtesy of FORD MOTOR CO.
  7. Install lip seal protector tools on the forward clutch piston.
    1. Install the special tool to the forward clutch piston outer seal.
    2. Install the special tool to the forward clutch piston inner seal.
    8. CAUTION: Care must be taken to prevent damage to the seals.
  8. As you install the forward clutch piston into the forward clutch cylinder, remove the special tools.
  9. Install the 15 forward clutch piston springs and the forward clutch piston spring retainer.
    1. Install the 15 forward clutch piston springs.
    2. Install the forward clutch piston spring retainer.
    Fig 7: Installing Forward Clutch Piston Springs & Retainer
    G02152899Courtesy of FORD MOTOR CO.
    10. CAUTION: Do not fully depress the special tool or damage to the spring retainer can occur.
    Fig 8: Installing Forward Clutch Piston Spring Retaining Ring
    G02152900Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the forward clutch piston spring retaining ring.
    11. CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise (I.D. to O.D.) and the word "TOP" facing up.
    CAUTION: If new plates are used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.
    Fig 9: Installing Friction Plates
    G02152901Courtesy of FORD MOTOR CO.
  11. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
  12. Install the steel clutch plates and friction clutch plates (quantity model dependent) in alternating order starting with a steel clutch plate.
    Fig 10: Installing Steel Clutch Plates & Friction Clutch Plates
    G02152902Courtesy of FORD MOTOR CO.
    13. CAUTION: The retaining ring is a select fit.
    Fig 11: Installing Forward Clutch Pressure Plate & Original Selective Retaining Ring
    G02152903Courtesy of FORD MOTOR CO.
  13. Install the forward clutch pressure plate and the original selective retaining ring.
    1. Install the forward clutch pressure plate.
    2. Install the forward clutch retaining ring.
    14. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.
    Fig 12: Air Checking Forward Clutch Piston
    G02152904Courtesy of FORD MOTOR CO.
  14. Air check the forward clutch piston.
    1. Place the forward clutch cylinder with forward clutch piston facing down.
    2. Install the transmission center support on the forward clutch cylinder.
    3. Apply air pressure to the left port of the center support.
  15. Check forward clutch disc pack free play.
    1. Press down on forward clutch disc pack.
    2. Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.
      • If the clearance is not within specifications, install the correct size retaining ring.
    Fig 13: Check Forward Clutch Disc Pack Free Play
    G02152905Courtesy of FORD MOTOR CO.
    Fig 14: Retaining Ring Thickness Specification
    G02152906Courtesy of FORD MOTOR CO.
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