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Forward Clutch Assembly: Disassembly

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.
  1. Remove the No. 9A forward clutch thrust bearing.
    Fig 1: Removing No. 9A Forward Clutch Thrust Bearing
    G01539225Courtesy of FORD MOTOR CO.
  2. Remove the No. 8B forward clutch needle bearing assembly.
    Fig 2: Removing No. 8B Forward Clutch Needle Bearing Assembly
    G01539226Courtesy of FORD MOTOR CO.
  3. Remove the 2 interlocking cast iron forward clutch cylinder seals.
    Fig 3: Removing Interlocking Cast Iron Forward Clutch Cylinder Seals
    G01539227Courtesy of FORD MOTOR CO.
  4. Remove the selective forward clutch pressure plate retaining ring.
    Fig 4: Removing Selective Forward Clutch Pressure Plate Retaining Ring
    G01539228Courtesy of FORD MOTOR CO.
    5. NOTE: Tag the parts for identification during installation.
    Fig 5: Removing Forward Clutch Pressure Plates
    G01539229Courtesy of FORD MOTOR CO.
  5. Remove the forward clutch pressure plates.
    1. Remove the top forward clutch pressure plate.
    2. Remove the clutch plates.
    3. Remove the forward clutch pressure spring.
    4. Remove the bottom forward clutch pressure plate.
  6. Remove the forward clutch piston return spring retaining ring.
    Fig 6: Removing Forward Clutch Piston Return Spring Retaining Ring
    G01539230Courtesy of FORD MOTOR CO.
  7. Remove the forward clutch piston return spring.
    Fig 7: Removing Forward Clutch Piston Return Spring
    G01539231Courtesy of FORD MOTOR CO.
  8. Remove the forward clutch piston apply ring.
    Fig 8: Removing Forward Clutch Piston Apply Ring
    G01539232Courtesy of FORD MOTOR CO.
  9. Using compressed air, remove the forward clutch piston.
    Fig 9: Removing Forward Clutch Piston Using Special Tool
    G01539233Courtesy of FORD MOTOR CO.
  10. Remove the outer forward clutch piston seal.
    Fig 10: Removing Outer Forward Clutch Piston Seal
    G01539234Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the forward clutch piston inner seal.
    Fig 11: Removing Forward Clutch Piston Inner Seal Using Special Tool
    G01539235Courtesy of FORD MOTOR CO.
  12. Inspect the clutch cylinder thrust surfaces, piston bore, and clutch plate splines for scores, burrs or wear. Install a new clutch cylinder if it is badly scored or damaged.
  13. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and install new, if necessary. Inspect the check balls for freedom of movement.
  14. Check the clutch release spring for distortion and cracks. Install a new spring if it is distorted or cracked.
  15. Inspect the friction clutch plates, steel clutch plates, and clutch pressure plate for worn or scored surfaces. Install new parts that are scored, burred or burnt.
  16. Check the clutch plates for flatness and wear on the clutch hub splines. Discard any plate that does not slide freely on the splines or that is not flat.
  17. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear. Install new parts that are worn.
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