Direct Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Lightly lubricate the new pistons with petroleum jelly.
- Direct clutch piston.
- Direct clutch return spring.
- Direct clutch balance piston.

Fig 1: Identifying Clutch Piston And Clutch Return Spring

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 Clutch Balance Piston And Return Spring

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.
- Externally splined steel plates.
- Internally splined friction plates.
- Pressure plate.

Fig 5: Installing Plates

Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.