Direct Clutch Assembly & Intermediate Brake Drum: Disassembly

WARNING: This page is about a different car, the 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the intermediate one-way clutch outer race, and inspect for damage.

Fig 1: Removing Intermediate One-Way Clutch Outer Race
Courtesy of FORD MOTOR CO.
Remove the top end cap and the intermediate one-way clutch. Inspect the sprags, cage, and top end cap for excessive wear or damage.

Fig 2: Removing Top End Cap And Intermediate One-Way Clutch
Courtesy of FORD MOTOR CO.
Remove the bottom end cap and inspect for damage.

Fig 3: Removing Bottom End Cap
Courtesy of FORD MOTOR CO.
Remove the No. 7 intermediate one-way clutch thrust washer.

Fig 4: Removing Intermediate One-Way Clutch Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the direct clutch pressure plate retaining ring.

Fig 5: Removing Direct Clutch Pressure Plate Retaining Ring
Courtesy of FORD MOTOR CO.

NOTE: Tag the parts for identification during installation.

Fig 6: Removing Direct Clutch Pressure Plate And Clutch Pack

Courtesy of FORD MOTOR CO.

Remove the direct clutch pressure plate and the clutch pack.

CAUTION: Do not fully compress the return springs or the spring may break.

Fig 7: Removing Direct Clutch Return Spring Retaining Ring

Courtesy of FORD MOTOR CO.

Using the special tool, remove the direct clutch return spring retaining ring. Remove the tool.
Remove the direct clutch return spring assembly.

Fig 8: Removing Direct Clutch Return Spring Assembly
Courtesy of FORD MOTOR CO.
Remove the direct clutch piston.

Fig 9: Removing Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Using the special tool, remove the direct clutch piston inner and outer seals.

Fig 10: Removing Direct Clutch Piston Inner And Outer Seals
Courtesy of FORD MOTOR CO.
Inspect the clutch cylinder thrust surfaces, piston bore, and clutch plate splines for scores, burrs or wear. Install a new clutch cylinder if it is 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 replace, if necessary. Inspect the check balls for freedom of movement.
Check the clutch release spring for distortion and cracks. Install a new spring if it is distorted or cracked.
Inspect the friction clutch plates, steel clutch plates, and clutch pressure plate for worn or scored surfaces. Install new parts that are scored, burred or burnt.
Check the clutch plates for flatness and wear on the clutch hub splines. Discard any plate that does not slide freely on the splines or that is not flat.
Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear. Install new parts that are worn.