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Intermediate Brake and Direct Clutch Drum Assembly: Disassembly

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 retaining ring is a select fit. See ASSEMBLY  if installation of new ring or clutch pack is required.
  1. Remove the direct clutch retaining ring and the direct clutch pressure plate.
    1. Remove the direct clutch retaining ring.
    2. Remove the direct clutch pressure plate.
      Fig 1: Removing Direct Clutch Retaining Ring And Direct Clutch Pressure Plate
      G03975327Courtesy of FORD MOTOR CO.
    2. CAUTION: Clutch plates are directional. Note the direction of the grooves for installation.
  2. Remove the direct clutch disc pack.
    • Inspect and install new steel and friction plates if worn, damaged or overheated.
    • Measure and record the thickness of the steel plates for assembly.
      Fig 2: Removing Direct Clutch Disc Pack
      G03975328Courtesy of FORD MOTOR CO.
    3. 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 3: Removing Direct Clutch Piston Retaining Ring
    G03975329Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the direct clutch piston retaining ring.
  4. Relieve the direct clutch spring tension and remove the special tool.
  5. Remove the direct clutch piston spring retainer and the 20 direct clutch piston springs.
    1. Lift the direct clutch piston spring retainer off the direct clutch piston springs.
    2. Remove the direct clutch piston springs.
      Fig 4: Removing Direct Clutch Piston Spring Retainer & Clutch Piston Springs
      G03975330Courtesy of FORD MOTOR CO.
    6. WARNING: Do not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.
  6. Using compressed air, remove the direct clutch piston from the intermediate brake and direct clutch drum.
    • Apply air pressure to the hole in the drum while blocking the other with a finger.
      Fig 5: Applying Air Pressure To Hole In Drum To Remove The Direct Clutch Piston
      G03975331Courtesy of FORD MOTOR CO.
  7. Remove the direct clutch piston inner and outer seal.
    1. Remove the direct clutch piston inner seal.
    2. Remove the direct clutch piston outer seal.
      Fig 6: Removing Direct Clutch Piston Inner And Outer Seal
      G03975332Courtesy of FORD MOTOR CO.
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