Disassembly Procedure

• Inspect the drum band surface, bushing, and thrust surfaces for damage.
• Inspect the clutch piston bore, and piston.
• Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
• Inspect the clutch plates for damage.
• Inspect the clutch springs.

1. Disassemble the parts in the order indicated in the following illustration and table. See Fig 1.
   Fig 1: Identifying Disassembling Sequence Of Direct Clutch Drum Assembly Parts

   Courtesy of FORD MOTOR CO.
2. To assemble, reverse the disassembly procedure.

Item 5: Retaining Ring Disassembly Note 

WARNING: Use caution when releasing tool pressure on the rear clutch piston spring. Failure to follow these instructions may result in personal injury.
CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.
Fig 2: Removing Coast Clutch Piston Retaining Ring
Courtesy of FORD MOTOR CO.
1. Using the special tool, remove the coast clutch piston retaining ring.

Item 8: Direct and Overdrive Clutch Piston Disassembly Note 

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.
Fig 3: Identifying Hole In Drum For Applying Air Pressure
Courtesy of FORD MOTOR CO.
1. Using compressed air, remove the direct clutch piston from the clutch drum.
   • Apply air pressure to the hole in the drum to remove the coast clutch piston while blocking the other hole with a finger.

Item 11: Overdrive Brake and Coast Clutch Drum Assembly Note 

1. Verify the check ball is free to move.
   Fig 4: Identifying Check Ball

   Courtesy of FORD MOTOR CO.

Items 9 and 10: Direct and Overdrive Piston Inner and Outer Seal Ring Assembly Note 

CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
NOTE: Use new seals to help prevent seal failures.
Fig 5: Installing New Direct Clutch Piston Inner Seal And Direct Clutch Piston Outer Seal
Courtesy of FORD MOTOR CO.
1. Lubricate the seals, then install the new direct clutch piston inner seal and the direct clutch piston outer seal.
CAUTION: Care must be taken to prevent damage to the seals during installation.
Fig 6: Installing Direct Clutch Piston
Courtesy of FORD MOTOR CO.
2. Using the special tool. Install the direct clutch piston.

Item 5: Retaining Ring Assembly Note 

WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.
CAUTION: Do not fully compress the special tool or damage to the coast clutch piston spring retainer may occur.
Fig 7: Installing Coast Clutch Piston Spring Retainer Ring
Courtesy of FORD MOTOR CO.
1. Using the special tool, install the coast clutch piston spring retainer ring.

Items 3 and 4: Coast Clutch External Steel Plate and Internal Friction Plate Assembly Note 

CAUTION: Coast clutch friction plates are directional and must be installed with grooves clockwise (I.D. to O.D.). The word "TOP" should face up.
CAUTION: If new clutch plates are being used, they should be soaked in clean automatic transmission fluid before assembly.
Fig 8: Installing Direct Clutch Disc Pack
Courtesy of FORD MOTOR CO.
1. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.
2. Install the two steel clutch plates and two friction clutch plates in an alternating order, starting with a steel clutch plate.
   Fig 9: Installing Friction Plates

   Courtesy of FORD MOTOR CO.

Item 1: Retaining Ring Assembly Note 

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.
Fig 10: Identifying Hole In Drum For Applying Air Pressure
Courtesy of FORD MOTOR CO.
1. Air check the assembly.
   • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
2. Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.
   • If specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge. See DIRECT CLUTCH THICKNESS AND DIAMETER .

Fig 11: Checking Gap Between Direct Clutch Retaining Ring And Direct Clutch Pressure Plate

Courtesy of FORD MOTOR CO.