Reverse Clutch: Assembly

WARNING: This page is about a different car, the 2002 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: One tab that locks the reverse clutch drum into the reverse sun shell may be removed. This is done for balancing purposes.

Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if badly scored or damaged.
Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and install new if necessary. Inspect the check balls for freedom of movement and correct seating.
Check the clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
Inspect the composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.

NOTE: The piston check ball must be present and moving freely.

Fig 1: Installing New Reverse Clutch Piston Inner And Outer Seals

Courtesy of FORD MOTOR CO.

Install a new reverse clutch piston inner and outer seals.

NOTE: Coat the reverse clutch piston inner seal, outer seal, drum sealing area and special tools with petroleum jelly.

Fig 2: Using Special Tools And Installing Reverse Clutch Piston

Courtesy of FORD MOTOR CO.

Using the special tools, install the reverse clutch piston using even pressure to push it to the bottom of the reverse clutch drum.

NOTE: The dished side of the reverse clutch piston spring must face the reverse clutch piston.

Install the reverse clutch piston spring.
1. Install the reverse clutch piston spring pressure ring.
2. Install the reverse clutch piston spring.
  
  Fig 3: Installing Reverse Clutch Piston Spring
  Courtesy of FORD MOTOR CO.
Using the special tools, compress the reverse clutch piston spring.

Fig 4: Using Special Tools And Compress Reverse Clutch Piston Spring
Courtesy of FORD MOTOR CO.
Install the reverse clutch piston spring retaining ring.

Fig 5: Installing Reverse Clutch Piston Spring Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the special tool.

CAUTION: Install the pressure plates with the flat sides facing the clutch pack.

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

Fig 6: Installing Reverse Clutch Front Pressure Plate, Clutch Pack And Reverse Clutch Rear Pressure Plate

Courtesy of FORD MOTOR CO.

Install the reverse clutch front pressure plate, clutch pack and reverse clutch rear pressure plate.
Install the reverse clutch pressure plate retainer snap ring.

Fig 7: Installing Reverse Clutch Pressure Plate Retainer Snap Ring
Courtesy of FORD MOTOR CO.
Install the special tool on the reverse clutch pack.
- Push downward on the clutch pack.
- Release pressure and zero the dial indicator.
  
  Fig 8: Installing Special Tool On Reverse Clutch Pack
  Courtesy of FORD MOTOR CO.
Using the special tool check the reverse clutch pack clearance.
1. Lift up on the clutch pack until it fully seats against the reverse clutch pressure plate retainer.
2. Read the dial indicator.
  - If clearance is not within specifications, install the correct size retaining ring.
    
    Fig 9: Using Special Tool Check Reverse Clutch Pack Clearance
    Courtesy of FORD MOTOR CO.
Selective Retaining Rings

Fig 10: Selective Retaining Rings Specification Table
Courtesy of FORD MOTOR CO.
Check the clutch for correct operation.
- Apply air pressure to the reverse clutch drum. The clutch should be heard and felt to work without leakage.
  
  Fig 11: Checking Clutch For Correct Operation
  Courtesy of FORD MOTOR CO.