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Disassemble and Assembly

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: If the seals on the forward clutch piston show any signs of damage, a new forward clutch piston must be installed.
NOTE: Inspect the clutch components for damage or wear. Install new components as necessary.
  • 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.
  • Inspect the needle bearing and seal rings for damage.
  • Check clutch hub thrust surfaces for damage.
  • Check clutch plates for flatness and fit on the clutch hub serrations.
  1. Disassemble the parts in the order indicated in the following illustration and table. See Fig 1.
    Fig 1: Identifying Removal Sequence Of Forward Clutch Components
    G03201916Courtesy 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 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 2: Removing Forward Clutch Piston Retaining Ring
    G03201917Courtesy of FORD MOTOR CO.
  1. Using the special tool, remove the forward clutch piston retaining ring.

Item 7: Forward Clutch Piston Disassembly Note 

    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 3: Removing Forward Clutch Piston
    G03201918Courtesy of FORD MOTOR CO.
  1. 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.

Item 8: Forward Clutch Cylinder Assembly Note 

  1. Inspect the forward clutch drum assembly.
    1. Inspect the forward clutch cylinder surfaces for scores or burrs.
    2. Inspect forward clutch piston for scores or burrs.
    3. Verify the check ball is free to move in the piston.
    Fig 4: Inspecting Forward Clutch Drum Assembly
    G03201919Courtesy of FORD MOTOR CO.

Item 7: Forward Clutch Piston Assembly Note 

    NOTE: The special tool must be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.
    Fig 5: Installing Special Tools On Forward Clutch Piston
    G03201920Courtesy of FORD MOTOR CO.
  1. Install the special tool on the forward clutch piston.
    2. CAUTION: Care must be taken to prevent damage to the seals.
    NOTE: Lubricate the forward clutch piston inner and outer seal with clean automatic transmission fluid.
    Fig 6: Installing Forward Clutch Piston Assembly Into Forward Clutch Cylinder
    G03201921Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.

Item 5: Retaining Ring Assembly Note 

    CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
    Fig 7: Installing Forward Clutch Piston Spring Retaining Ring
    G03201922Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the forward clutch piston spring retaining ring.

Items 4 and 3: Forward Clutch External/Internal Splined Friction and Steel Plates Assembly Note 

    CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise.
    CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.
    Fig 8: Installing Direct Clutch Disc Pack
    G03201923Courtesy of FORD MOTOR CO.
  1. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
  2. Install the steel clutch plates and friction clutch plates in an alternating order, starting with a steel clutch plate.
    Fig 9: Installing Steel Clutch Plates And Friction Clutch Plates
    G03201924Courtesy 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. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.
    Fig 10: Installing Transmission Center Support On Forward Clutch Cylinder
    G03201925Courtesy of FORD MOTOR CO.
  1. 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.
  2. 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. See Fig 11.
      • If the clearance is not within specifications, install the correct size retaining ring.
        FORWARD CLUTCH DISC PACK FREE PLAY SPECIFICATION

        Part Number Thickness Diameter
        mm In mm In
        XW4Z-7D483-AB 1.73 0.0681 141.45 5.65
        XW4Z-7D483-AC 2.08 0.0819 141.45 5.65
        XW4Z-7D483-AD 2.44 0.0961 141.45 5.65
    Fig 11: Checking Gap Between Forward Clutch Retaining Ring And Forward Clutch Pressure Plate
    G03201926Courtesy of FORD MOTOR CO.
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