Forward 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 faces toward the bottom of the cylinder. Make sure the check ball moves freely.

Fig 1: Installing Inner Piston Seal

Courtesy of FORD MOTOR CO.

Install a new inner piston seal.

NOTE: Lightly coat all the seals with petroleum jelly during assembly.

Fig 2: Installing Piston Assembly

Courtesy of FORD MOTOR CO.

Using the special tool install the piston assembly.
Install the clutch return spring.

Fig 3: Installing Clutch Return Spring
Courtesy of FORD MOTOR CO.

CAUTION: Do not fully compress the return spring retainer.

Fig 4: Installing Snap Ring

Courtesy of FORD MOTOR CO.

Using the special tool, install the snap ring.

NOTE: The quantity of the forward clutch are model dependent. The 3.0L 2V has 3 forward clutch plates and the 3.0L 4V has 4 forward clutch plates.

Install the forward clutch plates.
1. Install the clutch packs.
2. Install the pressure plate.
3. Install the retaining ring.
  
  Fig 5: Installing Forward Clutch Plates
  Courtesy of FORD MOTOR CO.
Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.

Fig 6: Measuring Clearance Between Retaining Ring And Clutch Cylinder Lip
Courtesy of FORD MOTOR CO.
If the clearance is not within specification selective retaining rings are available. Check the clearance after installing the correct selective retaining ring.

Fig 7: Selective Retaining Ring Specification
Courtesy of FORD MOTOR CO.