Reverse Clutch: 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: One tab that locks the reverse clutch drum into the reverse sun shell may be removed. This is done for balancing purposes.

Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if 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 and correct seating.
Check the clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
Inspect the composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.

NOTE: The piston check ball must be present and moving freely.

Fig 1: Installing Reverse Clutch Piston Inner And Outer Seals

Courtesy of FORD MOTOR CO.

Install a new reverse clutch piston inner and outer seals.

NOTE: Coat the reverse clutch piston inner seal, outer seal, drum sealing area and special tools with petroleum jelly.

Fig 2: Installing Reverse Clutch Piston

Courtesy of FORD MOTOR CO.

Using the special tools, install the reverse clutch piston using even pressure to push it to the bottom of the reverse clutch drum.

NOTE: The dished side of the reverse clutch piston spring must face the reverse clutch piston.

Fig 3: Installing Reverse Clutch Piston Spring

Courtesy of FORD MOTOR CO.

Install the reverse clutch piston spring.
1. Install the reverse clutch piston spring pressure ring.
2. Install the reverse clutch piston spring.
Using the special tools, compress the reverse clutch piston spring.

Fig 4: Compressing Reverse Clutch Piston Spring
Courtesy of FORD MOTOR CO.
Install the reverse clutch piston spring retaining ring.

Fig 5: Installing Reverse Clutch Piston Spring Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the special tool.

CAUTION: Install the pressure plates with the flat sides facing the clutch pack.

NOTE: Soak the new clutch discs in clean automatic transmission fluid.

Fig 6: Installing Reverse Clutch Front Pressure Plate

Courtesy of FORD MOTOR CO.

Install the reverse clutch front pressure plate, clutch pack and reverse clutch rear pressure plate.
Install the reverse clutch pressure plate retainer snap ring.

Fig 7: Installing Reverse Clutch Pressure Plate Retainer Snap Ring
Courtesy of FORD MOTOR CO.
Install the special tool on the reverse clutch pack.
- Push downward on the clutch pack.
- Release pressure and zero the dial indicator.
Fig 8: Pushing Downward On Clutch Pack
Courtesy of FORD MOTOR CO.

Using the special tool check the reverse clutch pack clearance.

Lift up on the clutch pack until it fully seats against the reverse clutch pressure plate retainer.

Read the dial indicator.

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

SELECTIVE RETAINING RINGS

SELECTIVE RETAINING RINGS SPECIFICATION CHART

Specification
1.52-1.62 mm (0.060-0.064 inch)
1.87-1.98 mm (0.074-0.078 inch)
2.23-2.33 mm (0.088-0.092 inch)
2.59-2.69 mm (0.102-0.106 inch)

Fig 9: Checking Reverse Clutch Pack Clearance

Courtesy of FORD MOTOR CO.

Check the clutch for correct operation.
- Apply air pressure to the reverse clutch drum. The clutch should be heard and felt to work without leakage.
Fig 10: Checking Clutch For Correct Operation
Courtesy of FORD MOTOR CO.