Direct Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 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.

Lightly lubricate the new pistons with petroleum jelly.
1. Direct clutch piston
2. Direct clutch return spring
3. Direct clutch balance piston
Fig 1: Identifying Direct Clutch Piston, Return Spring And Clutch Balance Piston
Courtesy of FORD MOTOR CO.
Install a new direct clutch piston.

Fig 2: Installing Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Install the direct clutch return spring and a new balance piston.

Fig 3: Installing Direct Clutch Return Spring And New Balance Piston
Courtesy of FORD MOTOR CO.
Using the special tools, install the snap ring.

Fig 4: Installing Snap Ring Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: The direct clutch plates are installed in an alternating sequence, starting with an externally splined steel plate, then an internally splined friction plate, with the pressure plate on the top just under the snap ring.

Fig 5: Identifying Externally Splined Steel Plates, Internally Splined Friction Plates And Pressure Plate

Courtesy of FORD MOTOR CO.

Install the plates.
1. Externally splined steel plates
2. Internally splined friction plates
3. Pressure plate
Install the snap ring.

Fig 6: Installing Snap Ring
Courtesy of FORD MOTOR CO.
Using a feeler gauge, measure the clearance between the snap ring and the pressure plate.

Fig 7: Measuring Clearance Between Snap Ring And Pressure Plate
Courtesy of FORD MOTOR CO.