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Forward/Coast/Direct Clutches: Disassembly

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the direct clutch pressure plate retaining ring.
    Fig 1: Locating Clutch Pressure Plate Retaining Ring
    G04620224Courtesy of FORD MOTOR CO.
  2. Disassemble the direct clutch pack.
    1. Remove the direct clutch pressure plate.
    2. Remove the direct clutch steel plates.
    3. Remove the direct clutch friction plates.
      Fig 2: Identifying Clutch Friction Plates
      G04620225Courtesy of FORD MOTOR CO.
    3. WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.
    CAUTION: Do not compress the direct clutch return springs completely.
  3. Remove the direct clutch spring retaining ring.
    1. Using the special tool, compress the direct clutch return springs.
    2. Remove the direct clutch return spring retaining ring.
      Fig 3: Removing Forward/Coast Clutch Return Spring Retaining Ring Using Special Tools
      G04620226Courtesy of FORD MOTOR CO.
  4. Remove the direct clutch return spring assembly.
    Fig 4: Locating Clutch Return Spring Assembly
    G04620227Courtesy of FORD MOTOR CO.
  5. Remove the direct clutch piston assembly.
    Fig 5: Locating Direct Clutch Piston Assembly
    G04620228Courtesy of FORD MOTOR CO.
  6. Remove and discard the direct clutch piston outer lip seal.
    Fig 6: Locating Clutch Piston Outer Lip Seal
    G04620229Courtesy of FORD MOTOR CO.
  7. Remove and discard the direct clutch piston inner lip seal from the forward/coast/direct clutch cylinder assembly.
    Fig 7: Locating Clutch Piston Inner Lip Seal
    G04620230Courtesy of FORD MOTOR CO.
  8. Remove the forward clutch pressure plate retaining ring.
    Fig 8: Locating Forward Clutch Pressure Plate Retaining Ring
    G04620231Courtesy of FORD MOTOR CO.
  9. Remove the forward and coast clutch plates.
    1. Forward clutch pressure plate
    2. Forward clutch external spline clutch plates (steel)
    3. Coast clutch internal spline clutch plates (friction)
    4. Coast clutch external spline clutch plates (steel)
    5. Coast clutch pressure plate
    6. Forward clutch wave spring
    7. Forward clutch internal spline clutch plates (friction)
      Fig 9: Identifying Clutch Pressure Plate
      G04620232Courtesy of FORD MOTOR CO.
    10. WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.
    CAUTION: Do not compress the return springs completely.
  10. Remove the forward/coast clutch return spring retaining ring.
    1. Using the special tool, compress the return spring.
    2. Remove the retaining ring.
      Fig 10: Removing Forward/Coast Clutch Return Spring Retaining Ring Using Special Tools
      G04620233Courtesy of FORD MOTOR CO.
  11. Remove the forward/coast clutch return spring assembly.
    Fig 11: Locating Forward/Coast Clutch Return Spring Assembly
    G04620234Courtesy of FORD MOTOR CO.
  12. Remove the forward and coast clutch pistons.
    Fig 12: Locating Forward & Coast Clutch Pistons
    G04620235Courtesy of FORD MOTOR CO.
  13. Using the special tool, remove and discard the forward clutch piston inner seal from the forward/coast/direct clutch cylinder assembly.
    Fig 13: Removing Forward Clutch Piston Inner Seal
    G04620236Courtesy of FORD MOTOR CO.
  14. Remove and discard the forward clutch piston outer lip seal.
    Fig 14: Identifying Clutch Piston Outer Lip Seal
    G04620237Courtesy of FORD MOTOR CO.
  15. Separate the coast clutch piston assembly from the forward clutch piston assembly.
    Fig 15: Removing Coast Clutch Piston Assembly
    G04620238Courtesy of FORD MOTOR CO.
    16. WARNING: When using compressed air, never let air pressure exceed 172 kPa (25 psi) and always wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to follow this instruction may result in serious personal injury.
    NOTE: Do not clean the clutch plates in a vapor degreaser or in any other type of detergent solution.
  16. Clean all parts thoroughly in a clean automatic transmission fluid and blow dry with moisture-free regulated compressed air.
    • Clean the steel clutch plates with a lint-free cloth.
    • Soak the new clutch plates in the specified transmission fluid before assembly.
  17. Inspect the parts for damage, cracks or wear.
    • Spline teeth
    • Clutch plates
    • Seals
    • Bushing
    • Check balls in pistons
    • Piston bore
    • Passages and lubrication holes in the forward/coast/direct clutch cylinder
    • Center hub weld
    • Large snap ring grooves
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