Forward 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 and seals with petroleum jelly.
1. Forward clutch balance piston
2. Forward clutch balance piston return spring
3. Forward clutch piston
  
  Fig 1: Identifying Pistons And Seals
  Courtesy of FORD MOTOR CO.
Install the forward clutch piston.

Fig 2: Installing Forward Clutch Piston
Courtesy of FORD MOTOR CO.
Install the forward clutch balance piston return spring and balance piston.

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

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

NOTE: Inspect the forward clutch plates for damage. If any damage is found, install new plates.

Install the forward clutch pack.
1. Cushion spring
2. Externally splined steel plates
3. Internally splined friction plates
4. Forward clutch pressure plate
  
  Fig 5: Identifying Cushion Spring, Externally Splined Steel Plates And Forward Clutch Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the forward clutch snap ring.

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

Fig 7: Measuring Clearance Between Snap Ring And Pressure Plate
Courtesy of FORD MOTOR CO.
Install the No. 8 forward clutch thrust bearing, blue side up.

Fig 8: Nonstaining. 8 Forward Clutch Thrust Bearing, Blue Side Up
Courtesy of FORD MOTOR CO.
Install the No. 7 thrust washer and two new seals.

Fig 9: Installing No. 7 Thrust Washer And Two New Seals
Courtesy of FORD MOTOR CO.