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Forward Clutch Assembly: 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.
  1. Install the forward clutch piston inner seal.
    Fig 1: Installing Forward Clutch Piston Inner Seal
    G01539236Courtesy of FORD MOTOR CO.
  2. Inspect the forward clutch piston check ball.
    • Check for freedom of movement and correct seating.
    • Clean with a suitable solvent, if necessary.
    • Replace the forward clutch piston assembly, if necessary.
    Fig 2: Inspecting Forward Clutch Piston Check Ball
    G01539237Courtesy of FORD MOTOR CO.
    3. NOTE: Make sure the seal lip is facing upward.
    Fig 3: Installing Forward Clutch Piston Outer Seal
    G01539238Courtesy of FORD MOTOR CO.
  3. Install the forward clutch piston outer seal.
  4. Using the special tool, install the forward clutch piston.
    Fig 4: Installing Forward Clutch Piston Using Special Tool
    G01539239Courtesy of FORD MOTOR CO.
  5. Install the steel forward clutch piston apply ring into the forward clutch piston groove.
    Fig 5: Installing Steel Forward Clutch Piston
    G01539240Courtesy of FORD MOTOR CO.
    6. CAUTION: To ensure durability, the notch between the spring fingers must be positioned so that both ends of the forward clutch piston apply ring are visible.
    Fig 6: Installing Forward Clutch Piston Return Spring
    G01539241Courtesy of FORD MOTOR CO.
  6. Install the forward clutch piston return spring.
    1. Install the forward clutch piston return spring, with the spring fingers against the forward clutch piston apply ring.
    2. Make sure the notch is positioned so that both ends of the forward clutch piston apply ring are visible.
  7. Install the forward clutch piston return spring retaining ring. Make sure it is correctly seated in the groove.
    Fig 7: Installing Forward Clutch Piston Return Spring Retaining Ring
    G01539242Courtesy of FORD MOTOR CO.
    8. NOTE: Soak the clutch plates for 15 minutes in clean automatic transmission fluid.
    Fig 8: Installing Forward Clutch Pressure Plates
    G01539243Courtesy of FORD MOTOR CO.
  8. Install the forward clutch pressure plates.
    1. Install the bottom forward clutch pressure plate.
    2. Install the forward clutch pressure spring.
    3. Install the forward clutch pressure plates.
    4. Install the top forward clutch pressure plate.
  9. Install the selective forward clutch pressure plate retaining ring.
    Fig 9: Installing Selective Forward Clutch Pressure Plate Retaining Ring
    G01539244Courtesy of FORD MOTOR CO.
  10. Check the stack-up clearance.
    • Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart.
    • If the clearance is not to specification, install the correct selective forward 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 10: Checking Stack-Up Clearance Using Feeler Gauge
    G01539245Courtesy of FORD MOTOR CO.
    11. NOTE: Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly.
    NOTE: The bearing large inner diameter radius must face inward.
    Fig 11: Installing No. 8B Forward Clutch Needle Bearing
    G01539246Courtesy of FORD MOTOR CO.
  11. Install the No. 8B forward clutch needle bearing.
    12. NOTE: Stagger the interlocking opening on the seals 180 degrees apart.
    Fig 12: Installing Cast Iron Forward Clutch Cylinder Seals In Grooves
    G01539247Courtesy of FORD MOTOR CO.
  12. Install the two new cast iron forward clutch cylinder seals in the grooves.
    13. NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.
    NOTE: The black side of the bearing must face upward.
    Fig 13: Installing No. 9A Forward Clutch Thrust Bearing
    G01539248Courtesy of FORD MOTOR CO.
  13. Install the No. 9A forward clutch thrust bearing.
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