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Forward Clutch: Disassembly

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.
Fig 1: Identifying Forward Clutch Assembly Components
G02152882Courtesy of FORD MOTOR CO.
    CAUTION: The retaining ring is a select fit. See assembly procedure if installation of a new ring or clutch plate pack is required.
    Fig 2: Removing Forward Clutch Pressure Plate
    G02152883Courtesy of FORD MOTOR CO.
  1. Remove the forward clutch pressure plate.
    1. Remove the forward clutch retaining ring.
    2. Remove the forward clutch pressure plate.
    2. CAUTION: If new plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.
    CAUTION: Clutch discs are directional. Note direction of grooves for installation.
    Fig 3: Removing Forward Clutch Disc Pack
    G02152884Courtesy of FORD MOTOR CO.
  2. Remove the forward clutch disc pack.
    • Inspect the forward clutch plates for wear, damage or overheating.
    3. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.
    CAUTION: Do not fully depress the special tool or damage to the spring retainer may occur.
    Fig 4: Removing Forward Clutch Piston Retaining Ring
    G02152885Courtesy of FORD MOTOR CO.
  3. Using the special tool to remove the forward clutch piston retaining ring.
  4. Relieve the forward clutch spring tension and remove the special tool.
  5. Remove the forward clutch piston spring retainer and 15 forward clutch piston springs.
    1. Remove the forward clutch piston spring retainer.
    2. Remove the 15 forward clutch piston springs.
      • Inspect the forward clutch piston springs for distortion.
    Fig 5: Removing Forward Clutch Piston Retainer & Springs
    G02152886Courtesy of FORD MOTOR CO.
    6. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.
    Fig 6: Removing Forward Clutch Piston
    G02152887Courtesy of FORD MOTOR CO.
  6. Remove the forward clutch piston.
    1. Place the forward clutch cylinder with forward clutch piston facing down.
    2. Install the center support on the forward clutch cylinder.
    3. Apply air pressure to the left port of the center support.
  7. Remove and discard the forward clutch piston seals.
    1. Remove the forward clutch piston outer seal and inspect the forward clutch piston for cracks.
    2. Remove forward clutch cushion spring.
    3. Remove the forward clutch piston inner seal.
    Fig 7: Removing Forward Clutch Piston Outer & Inner Seal
    G02152888Courtesy of FORD MOTOR CO.
  8. Inspect the remaining forward clutch drum components for damage or wear, install new components as necessary.
    1. Inspect the forward clutch cylinder surfaces for scores or burrs. Minor scores or burrs can be removed with a crocus cloth. Install a new forward clutch cylinder if it is badly scored or damaged.
    2. Inspect forward clutch piston for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Install a new forward clutch cylinder if it is badly scored or damaged.
    3. Make sure the check ball is free and clear of debris, has freedom of movement, and is correctly seated.
    Fig 8: Inspecting Forward Clutch Drum Components
    G02152889Courtesy of FORD MOTOR CO.
  9. Inspect the forward clutch drum components.
    • Inspect clutch plate serration for scores or burrs.
    • Inspect fluid passages for obstructions. Clean out all passages.
    • Inspect the friction clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surface. Install new parts that are deeply scored.
    • Check clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.
    • Check clutch hub thrust surfaces for scores and clutch hub splines for wear.
    • Inspect for damage or wear to the clutch disc grooves and retaining ring grooves.
    10. NOTE: Inspect the needle bearing for damage and install new if necessary.
    Fig 9: Inspecting Needle Bearing For Damage
    G02152890Courtesy of FORD MOTOR CO.
  10. Inspect the needle bearing for damage.
    11. CAUTION: Do not overtighten the tool or damage to the forward clutch bearing can occur.
    NOTE: This step only needs to be carried out if there is damage to the bearing.
    Fig 10: Removing Forward Clutch Bearing
    G02152891Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the forward clutch bearing.
    12. NOTE: This step only needs to be carried out if there is damage to the bearing.
    Fig 11: Inspecting Forward Clutch Outer Race
    G02152892Courtesy of FORD MOTOR CO.
  12. Inspect the forward clutch outer race for scoring or nicks, if any damage is found installation of a new forward clutch drum will needed.
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