Direct Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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: Assembling Lubricate New Pistons With Petroleum Jelly
  Courtesy of FORD MOTOR CO.
Install a new direct clutch piston.

Fig 2: Locating 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 Balance Piston
Courtesy of FORD MOTOR CO.
Using the special tools, install the snap ring.

Fig 4: Identifying Snap Ring With Special Tools
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.

Install the plates.
1. Externally splined steel plates
2. Internally splined friction plates
3. Pressure plate
  
  Fig 5: Installing Plates
  Courtesy of FORD MOTOR CO.
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.