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Intermediate Brake and Direct Clutch Drum Assembly: Assembly

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    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 1: Installing Direct Clutch Piston Inner Seal And Direct Clutch Piston Outer Seal
    G03975333Courtesy of FORD MOTOR CO.
  1. Install the new direct clutch piston inner seal and the direct clutch piston outer seal.
    2. CAUTION: Lubricate the direct clutch piston inner and outer seals with clean automatic transmission fluid.
    Fig 2: Installing Direct Clutch Piston Into Special Tool
    G03975334Courtesy of FORD MOTOR CO.
  2. Install the direct clutch piston into the special tool.
  3. Inspect the intermediate brake and direct clutch drum and components for the following:
    • Intermediate brake and direct clutch band surface for scoring.
    • Clutch piston bore and the piston inner and outer bearing surfaces for scoring.
    • The fluid passages for obstructions. All fluid passages must be clean and free of debris.
    • Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations. Install new plates that are badly scored, worn or do not fit freely in the hub serrations.
    • Inspect the direct clutch pressure plate for scores on the clutch plate bearing surface. Check the clutch release springs for distortion.
    • Verify that the intermediate brake and direct clutch drum check ball is clean and free of foreign material.
      Fig 3: Verifying Intermediate Brake And Direct Clutch Drum Check Ball Is Clean And Free Of Foreign Material
      G03975335Courtesy of FORD MOTOR CO.
  4. Carefully remove the direct clutch piston from the special tool.
    Fig 4: Removing Direct Clutch Piston From Special Tool
    G03975336Courtesy of FORD MOTOR CO.
    5. CAUTION: Care must be taken to prevent damage to the seals during installation.
  5. Install the direct clutch piston.
    1. Position the direct clutch piston in the intermediate brake and direct clutch drum.
    2. Push down evenly around the piston circumference.
      Fig 5: Installing Direct Clutch Piston
      G03975337Courtesy of FORD MOTOR CO.
  6. Install the direct clutch piston spring retainer and the 20 direct clutch piston springs.
    1. Install the direct clutch piston springs.
    2. Place the direct clutch piston spring retainer on the direct clutch piston springs.
      Fig 6: Installing Direct Clutch Piston Spring Retainer And Direct Clutch Piston Springs
      G03975338Courtesy of FORD MOTOR CO.
    7. 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 spring retainer may occur.
    Fig 7: Installing Direct Clutch Piston Retaining Ring
    G03975339Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the direct clutch piston retaining ring.
  8. Relieve the direct clutch spring tension and remove the special tool.
    9. CAUTION: The direct clutch friction plates are directional and must be installed with grooves pointing clockwise (I.D. to O.D.) and the word "TOP" facing up.
    CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.
    Fig 8: Ensuring Word "TOP" Is Facing Up
    G03975340Courtesy of FORD MOTOR CO.
  9. When installing new friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the direct clutch disc pack.
    10. NOTE: If new steel plates are being installed, make sure to use the correct steel plates. Use 2.14 mm (0.08 in) steel plates.
    Fig 9: Installing Steel Clutch Plates And Friction Clutch Plates
    G03975341Courtesy of FORD MOTOR CO.
  10. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
    11. CAUTION: The retaining ring is a select fit.
  11. Install the direct clutch pressure plate.
    1. Install the direct clutch pressure plate.
    2. Install the original direct clutch retaining ring on the direct clutch disc pack.
      Fig 10: Installing Direct Clutch Pressure Plate
      G03975342Courtesy of FORD MOTOR CO.
    12. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.
    NOTE: The direct clutch piston must apply with air pressure and release when the air is removed.
  12. Check the operation using compressed air.
    • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
      Fig 11: Checking Operation Using Compressed Air
      G03975343Courtesy of FORD MOTOR CO.
  13. 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.

      DIRECT CLUTCH 

      Fig 12: Checking Direct Clutch Retaining Ring To Direct Clutch Pressure Plate Gap
      G03975344Courtesy of FORD MOTOR CO.
      DIRECT CLUTCH RETAINING RING THICKNESS CHART

      Part Number Thickness Diameter
      mm In mm In
      E860126-S 1.37 0.0539 130.1 5.122
      E860127-S 1.73 0.0681 130.1 5.122
      E860128-S 2.08 0.0819 130.1 5.122
      E860129-S 2.44 0.0961 130.1 5.122
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