Intermediate/Overdrive Cylinder Assembly: 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.
- Lubricate with petroleum jelly or equivalent. Install the intermediate clutch piston outer seal, with the lip seal facing upward.
- Lubricate with petroleum jelly or equivalent. Install the intermediate clutch piston inner seal, with the lip seal facing downward toward the cylinder.
- Install the intermediate clutch piston.
- Lubricate seal with petroleum jelly or equivalent. Position the overdrive clutch piston and seal assembly onto the intermediate/overdrive cylinder at a slight angle. Then, rotate the piston while pressing it down until fully seated onto the cylinder.
- Install the overdrive clutch piston return spring.
- Using the special tools, compress the overdrive clutch piston return spring.
- Install the overdrive clutch piston return spring retainer. Make sure the retainer is fully seated, then remove the tools.
NOTE:
Prior to reassembly, inspect the check ball, the cup plugs and the feedbolt threads for contamination or damage. Clean or replace, as necessary.
NOTE:
The piston should rotate freely in the cylinder.
CAUTION:
The overdrive piston lip seals are bonded to the piston. Use care not to damage or roll the lip seal over.
NOTE:
The overdrive clutch piston return spring must be installed with fingers facing upward.