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Direct Clutch Assembly And Intermediate Brake Drum: Assembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Soak the clutch plates for 15 minutes in clean automatic transmission fluid.
    NOTE: The seal lip must face downward.
    Fig 1: Installing Direct Clutch Piston Inner Seal
    G01539209Courtesy of FORD MOTOR CO.
  1. Install the direct clutch piston inner seal.
    2. NOTE: The seal lip must face downward.
    Fig 2: Installing Direct Clutch Piston Outer Seal
    G01539210Courtesy of FORD MOTOR CO.
  2. Install the direct clutch piston outer seal.
  3. 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
    G01539211Courtesy of FORD MOTOR CO.
    4. NOTE: The piston should rotate freely in the drum.
    Fig 4: Installing Direct Clutch Piston
    G01539212Courtesy of FORD MOTOR CO.
  4. Install the direct clutch piston.
    5. 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
    G01539213Courtesy of FORD MOTOR CO.
  5. Install the direct clutch return spring assembly.
    6. CAUTION: Do not fully compress the return springs or damage to spring may occur.
    Fig 6: Installing Direct Clutch Return Spring Retaining Ring Using Special Tool
    G01539214Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the direct clutch return spring retaining ring. Remove the tool.
    7. CAUTION: Mixing or using friction plates without the grooves will cause shift concerns and can cause damage.
    NOTE: Soak the clutch plates for 15 minutes 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: Installing Steel And Friction Clutch Plates, Beginning With Steel Plate
    G01539215Courtesy of FORD MOTOR CO.
  7. Alternately install the steel and the friction clutch plates, beginning with a steel plate and ending with the direct clutch pressure plate.
  8. Install the selective direct clutch pressure plate retaining ring.
    Fig 8: Installing Selective Direct Clutch Pressure Plate Retaining Ring
    G01539216Courtesy of FORD MOTOR CO.
  9. 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 CLUTCH PLATE USAGE AND CLEARANCE  in SPECIFICATIONS  for selective snap ring thicknesses and part numbers.
    Fig 9: Checking Stack-Up Clearance Using Feeler Gauge
    G01539217Courtesy of FORD MOTOR CO.
  10. 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 No. 7 Intermediate One-Way Clutch Thrust Washer
    G01539218Courtesy of FORD MOTOR CO.
    11. NOTE: The top and bottom end caps are identical.
    Fig 11: Installing Bottom End Cap
    G01539219Courtesy of FORD MOTOR CO.
  11. Install the bottom end cap.
    12. NOTE: The lip on the intermediate one-way clutch must face upward.
    Fig 12: Installing Intermediate One-Way Clutch Over Inner Race
    G01539220Courtesy of FORD MOTOR CO.
  12. Install the intermediate one-way clutch over the inner race and install the top end cap.
    13. 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
    G01539221Courtesy of FORD MOTOR CO.
  13. Install the intermediate one-way clutch outer race.
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