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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 325 (Automatic Transmission - 4R70W) >> Disassembly And Assembly Of Subassemblies >> Output Shaft and Direct Clutch Cylinder >> Assembly

Output Shaft and Direct Clutch Cylinder: Assembly

WARNING: This page is about a different car, the 2003 Ford Econoline. 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.
  1. Using the special tool, install the inner piston seal.
    • Install the seal with sealing lip facing down.
      Fig 1: Installing Seal With Sealing Lip Facing Down
      G01539932Courtesy of FORD MOTOR CO.
  2. 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
    G01539933Courtesy of FORD MOTOR CO.
    3. 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
    G01539934Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the direct clutch piston.
  4. Install the piston return spring and retainer assembly.
  5. Using the special tool, compress the piston return spring and install the retaining ring.
    Fig 4: Installing Retaining Ring
    G01539935Courtesy of FORD MOTOR CO.
    6. NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid for 15 minutes.
  6. 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.
      Fig 5: Installing Clutch Pack Retaining Ring
      G01539936Courtesy of FORD MOTOR CO.
    3. 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.

        SELECTIVE RETAINING RING 

        Fig 6: Selective Retaining Ring Specification
        G01554490Courtesy of FORD MOTOR CO.
        Fig 7: Checking Clearance Between Clutch Pack Selective Retaining Ring And Pressure Plate
        G01539937Courtesy of FORD MOTOR CO.
    4. 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
        G01539938Courtesy of FORD MOTOR CO.
        NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.
      5. CAUTION: Make sure the seals are lapped correctly. Internal damage may occur.
      Fig 9: Installing Two Direct Clutch Seal Rings
      G01539939Courtesy of FORD MOTOR CO.
    5. Install the two direct clutch seal rings
    6. Install the output shaft hub.
      • Position the output shaft hub.
      • Install the retaining ring.
        Fig 10: Installing Output Shaft Hub
        G01539940Courtesy of FORD MOTOR CO.
    7. Install the three output shaft seal rings.
      Fig 11: Installing Three Output Shaft Seal Rings
      G01539941Courtesy of FORD MOTOR CO.
    8. Install the No. 8 needle bearing on the direct clutch cylinder.
      Fig 12: Installing No. 8 Needle Bearing On Direct Clutch Cylinder
      G01539942Courtesy of FORD MOTOR CO.
      9. 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
      G01539943Courtesy of FORD MOTOR CO.
    9. Assemble the direct clutch on the output shaft.
      10. 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
      G01539944Courtesy of FORD MOTOR CO.
    10. Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.
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