Output Shaft and Direct Clutch Cylinder: Assembly

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

NOTE: Lubricate the direct clutch piston inner seal and seal protector with petroleum jelly.

Fig 1: Installing Seal With Sealing Lip Facing Down

Courtesy of FORD MOTOR CO.

Using the special tool, install the inner piston seal.
- Install the seal with sealing lip facing down.
Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder.

Fig 2: Installing Clutch Piston Outer Seal
Courtesy of FORD MOTOR CO.

NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.

Fig 3: Installing Direct Clutch Piston

Courtesy of FORD MOTOR CO.

Using the special tool, install the direct clutch piston.
Install the piston return spring and retainer assembly.
Using the special tool, compress the piston return spring and install the retaining ring.

Fig 4: Installing Piston Return Spring And Retainer Assembly
Courtesy of FORD MOTOR CO.

NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid.

Fig 5: Installing Clutch Pack Retaining Ring

Courtesy of FORD MOTOR CO.

Install the clutch pack retaining ring.
1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
2. Install the clutch pack retaining ring.

Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate.

If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.

SELECTIVE RETAINING RING

SELECTIVE RETAINING RING SPECIFICATIONS CHART

Specification
1.52-1.62 mm (0.060-0.064 inch)
1.87-1.98 mm (0.074-0.078 inch)
2.23-2.69 mm (0.086-0.106 inch)
12.59-2.69 mm (0.102-0.106 inch)

Fig 6: Checking Clearance Between Clutch Pack Selective Retaining Ring And Pressure Plate

Courtesy of FORD MOTOR CO.

Install the direct clutch hub.
1. Install the No. 7 direct clutch inner bearing support.
2. Install the direct clutch hub.
Fig 7: Installing Direct Clutch Hub
Courtesy of FORD MOTOR CO.

NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.
Using the special tools, install the first direct clutch seal ring.

Fig 8: Installing First Direct Clutch Seal Ring
Courtesy of FORD MOTOR CO.
Using the special tools, install the second direct clutch seal ring.

Fig 9: Installing Second Direct Clutch Seal Ring
Courtesy of FORD MOTOR CO.
After both new seals have been installed, use the special tool to size the seals.

Fig 10: Identifying Seals Size
Courtesy of FORD MOTOR CO.
Install the output shaft hub.
- Position the output shaft hub.
- Install the retaining ring.
Fig 11: Installing Retaining Ring
Courtesy of FORD MOTOR CO.
Install the three output shaft seal rings.

Fig 12: Installing Output Shaft Seal Rings
Courtesy of FORD MOTOR CO.
Install the No. 8 needle bearing on the direct clutch cylinder.

Fig 13: Installing Needle Bearing On Direct Clutch Cylinder
Courtesy of FORD MOTOR CO.

NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.

Fig 14: Assembling Direct Clutch On Output Shaft

Courtesy of FORD MOTOR CO.

Assemble the direct clutch on the output shaft.

CAUTION: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear.

Fig 15: Aligning Index Marks On Output Shaft

Courtesy of FORD MOTOR CO.

Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.