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Home >> Ford >> 2002 >> Taurus SES, 3.0 S >> Repair and Diagnosis >> External Pages >> Different car >> Section 462 (Automatic Transmission - 4F50N) >> Disassembly And Assembly Of Subassemblies >> Direct Clutch Cylinder >> Assembly

Direct Clutch Cylinder: Assembly

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: The lip on the seal must face toward the bottom of the clutch cylinder.
    Fig 1: Installing Inner Piston Seal
    G01576123Courtesy of FORD MOTOR CO.
  1. Install the inner piston seal.
    2. NOTE: Make sure that the check ball is in place on the clutch piston. Lightly coat all the seals with petroleum jelly prior to installation.
    Fig 2: Installing Direct Clutch Piston And Seal Assembly
    G01576124Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the direct clutch piston and seal assembly making sure that it is fully seated.
  3. Install the apply ring. Make sure that it is fully seated on the clutch piston.
    Fig 3: Installing Apply Ring
    G01576125Courtesy of FORD MOTOR CO.
    4. NOTE: The notch on the direct clutch return spring must line up with the check ball on the direct clutch piston.
    Fig 4: Installing Direct Clutch Return Spring
    G01576126Courtesy of FORD MOTOR CO.
  4. Install the direct clutch return spring.
    5. CAUTION: Do not allow the Clutch Spring Compressor to bottom out on the piston.
    Fig 5: Installing Snap Ring
    G01576127Courtesy of FORD MOTOR CO.
  5. Using the special tool and snap ring pliers, compress the clutch spring and install the snap ring.
    6. CAUTION: Check for wear on the inner splines of the friction plates. Replace if worn.
    NOTE: The number of clutch plates may vary with application.
    NOTE: The clutch pressure plate must be installed with the chamfer edge facing up.
  6. Install the intermediate clutch pack.
    1. Install the intermediate clutch pack.
    2. Install the clutch pressure plate.
    3. Install the snap ring.
      Fig 6: Installing Intermediate Clutch Pack
      G01576128Courtesy of FORD MOTOR CO.
  7. Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.
    Fig 7: Measuring Clearance Between Retaining Ring And Clutch Cylinder Lip
    G01576129Courtesy of FORD MOTOR CO.
  8. If the clearance is not within specification, selective retaining rings are available. Check the clearance after installing the correct selective retaining ring.
    Fig 8: Selective Retaining Ring Specification
    G01576130Courtesy of FORD MOTOR CO.
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