Direct Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2011 Ford F550 Super Duty and 2011 Ford F450 Super Duty. 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: Identifying Direct Clutch Piston, Direct Clutch Return Spring And Direct Clutch Balance Piston
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: Locating Direct Clutch Balance Piston And Return Spring
Courtesy of FORD MOTOR CO.
Using the Clutch Spring Compressor Aligner and the Clutch Spring Compressor, install the snap ring.

Fig 4: Remove/Install Snap Ring Using Clutch Spring Compressor Aligner And The Clutch Spring Compressor
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.

Fig 5: Identifying Externally Splined Steel Plates, Internally Splined Friction Plates And Pressure Plate

Courtesy of FORD MOTOR CO.

Install the plates.
1. Externally splined steel plates.
2. Internally splined friction plates.
3. Pressure plate.
Install the snap ring.

Fig 6: Locating 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 Using Feeler Gauge With Specifications
Courtesy of FORD MOTOR CO.