Forward Clutch Assembly: 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 No. 9A forward clutch thrust bearing.

Fig 1: Removing Forward Clutch Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the No. 8B forward clutch needle bearing assembly.

Fig 2: Removing Forward Clutch Needle Bearing Assembly
Courtesy of FORD MOTOR CO.
Remove the 2 interlocking cast iron forward clutch cylinder seals.

Fig 3: Removing Interlocking Cast Iron Forward Clutch Cylinder Seals
Courtesy of FORD MOTOR CO.
Remove the selective forward clutch pressure plate retaining ring.

Fig 4: Removing Selective Forward Clutch Pressure Plate Retaining Ring
Courtesy of FORD MOTOR CO.

NOTE: Tag the parts for identification during installation.

Fig 5: Removing Forward Clutch Pressure Plates

Courtesy of FORD MOTOR CO.

Remove the forward clutch pressure plates.
1. Remove the top forward clutch pressure plate.
2. Remove the clutch plates.
3. Remove the forward clutch pressure spring.
4. Remove the bottom forward clutch pressure plate.
Remove the forward clutch piston return spring retaining ring.

Fig 6: Removing Forward Clutch Piston Return Spring Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the forward clutch piston return spring.

Fig 7: Removing Forward Clutch Piston Return Spring
Courtesy of FORD MOTOR CO.
Remove the forward clutch piston apply ring.

Fig 8: Removing Forward Clutch Piston Apply Ring
Courtesy of FORD MOTOR CO.
Using compressed air, remove the forward clutch piston.

Fig 9: Removing Forward Clutch Piston
Courtesy of FORD MOTOR CO.
Remove the outer forward clutch piston seal.

Fig 10: Removing Outer Forward Clutch Piston Seal
Courtesy of FORD MOTOR CO.
Using the special tool, remove the forward clutch piston inner seal.

Fig 11: Removing Forward Clutch Piston Inner Seal
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 install new, 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.