Direct Clutch Assembly & Intermediate Brake Drum: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Soak the clutch plates in clean automatic transmission fluid.

NOTE: The seal lip must face downward.

Fig 1: Installing Direct Clutch Piston Inner Seal

Courtesy of FORD MOTOR CO.

Install the direct clutch piston inner seal.

NOTE: The seal lip must face downward.

Fig 2: Installing Direct Clutch Piston Outer Seal

Courtesy of FORD MOTOR CO.

Install the direct clutch piston outer seal.
Inspect the direct clutch piston check ball.
- Check for freedom of movement and correct seating.
- Clean the direct clutch piston with solvent, if necessary.
- Install a new direct clutch piston, if damaged.
  
  Fig 3: Inspecting Direct Clutch Piston Check Ball
  Courtesy of FORD MOTOR CO.

NOTE: The piston should rotate freely in the drum.

Fig 4: Installing Direct Clutch Piston

Courtesy of FORD MOTOR CO.

Install the direct clutch piston.

NOTE: Make sure the protrusions on the bottom of the direct clutch return spring assembly are correctly engaged with the lugs on the direct clutch piston.

Fig 5: Installing Direct Clutch Return Spring Assembly

Courtesy of FORD MOTOR CO.

Install the direct clutch return spring assembly.

CAUTION: Do not fully compress the return springs or damage to spring may occur.

Fig 6: Installing Direct Clutch Return Spring Retaining Ring

Courtesy of FORD MOTOR CO.

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

CAUTION: Mixing or using friction plates without the grooves will cause shift concerns and can cause damage.

NOTE: Soak the clutch plates in clean automatic transmission fluid.

NOTE: The direct clutch friction plates have lube grooves in the friction material.

NOTE: The number of plates are model dependent.

Fig 7: Identifying Steel Plate And Ending With Direct Clutch Pressure Plate

Courtesy of FORD MOTOR CO.

Alternately install the steel and the friction clutch plates, beginning with a steel plate and ending with the direct clutch pressure plate.
Install the selective direct clutch pressure plate retaining ring.

Fig 8: Installing Selective Direct Clutch Pressure Plate Retaining Ring
Courtesy of FORD MOTOR CO.
Check the stack-up clearance.
1. Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart.
2. If the clearance is not to specification, install the correct selective direct clutch pressure plate retaining ring and recheck the clearance. Refer to the Direct Clutch Pack .
  
  Fig 9: Checking Stack-Up Clearance In Places
  Courtesy of FORD MOTOR CO.
Install the No. 7 intermediate one-way clutch thrust washer. Make sure the tabs on the No. 7 intermediate one-way clutch thrust washer are aligned with the notches in the intermediate brake drum.

Fig 10: Installing Intermediate One-Way Clutch Thrust Washer
Courtesy of FORD MOTOR CO.

NOTE: The top and bottom end caps are identical.

Fig 11: Installing Bottom End Cap

Courtesy of FORD MOTOR CO.

Install the bottom end cap.

NOTE: The lip on the intermediate one-way clutch must face upward.

Fig 12: Installing Intermediate One-Way Clutch Over Inner Race

Courtesy of FORD MOTOR CO.

Install the intermediate one-way clutch over the inner race and install the top end cap.

NOTE: The shoulder on the outer race must face upward.

NOTE: When installed correctly, the outer race must rotate counterclockwise.

Fig 13: Installing Intermediate One-Way Clutch Outer Race

Courtesy of FORD MOTOR CO.

Install the intermediate one-way clutch outer race.