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Intermediate Brake and Direct Clutch Drum Assembly: Assembly

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Locating New Coast Clutch Piston Inner & Outer Seal
GF0010199Courtesy of FORD MOTOR CO.
    CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover or damage of the lip seal.
    NOTE: Use new seals to help prevent seal failures.
  1. Install the new direct clutch piston inner seal and the direct clutch piston outer seal.
    2. Fig 2: Installing Direct Clutch Piston Into Special Tool (307-335)
    GF0010215Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the direct clutch piston inner and outer seals with clean automatic transmission fluid.
  2. Install the direct clutch piston into the special tool.
    3. Fig 3: Verifying That Intermediate Brake & Direct Clutch Drum Check Ball Is Clean & Free Of Foreign Material
    GF0010216Courtesy of FORD MOTOR CO.
  3. Inspect the intermediate brake and direct clutch drum and components for the following:
    • Intermediate brake and direct clutch band surface for scoring.
    • Clutch piston bore and the piston inner and outer bearing surfaces for scoring.
    • The fluid passages for obstructions. All fluid passages must be clean and free of foreign material.
    • Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations.
    • Inspect the direct clutch pressure plate for scores on the clutch plate bearing surface. Check the clutch release springs for distortion.
    • Verify that the intermediate brake and direct clutch drum check ball is clean and free of foreign material.
    4. Fig 4: Removing Direct Clutch Piston From Special Tool (307-335)
    GF0010215Courtesy of FORD MOTOR CO.
  4. Carefully remove the direct clutch piston from the special tool.
    5. Fig 5: Positioning Direct Clutch Piston In Intermediate Brake & Direct Clutch Drum
    GF0010217Courtesy of FORD MOTOR CO.
    CAUTION: Care must be taken to prevent damage to the seals during installation.
  5. Install the direct clutch piston.
    1. Position the direct clutch piston in the intermediate brake and direct clutch drum.
    2. Push down evenly around the piston circumference.
    6. Fig 6: Locating Direct Clutch Piston Spring Retainer
    GF0010212Courtesy of FORD MOTOR CO.
  6. Install the direct clutch piston spring retainer and the 20 direct clutch piston springs.
    1. Install the direct clutch piston springs.
    2. Place the direct clutch piston spring retainer on the direct clutch piston springs.
    7. Fig 7: Identifying Special Tool (307-015) And Direct Clutch Piston Retaining Ring
    GF0010211Courtesy of FORD MOTOR CO.
    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 fully compress the special tool or damage to the spring retainer may occur.
  7. Using the special tool, install the direct clutch piston retaining ring.
  8. Relieve the direct clutch spring tension and remove the special tool.
    9. Fig 8: Installing Grooves Clockwise & Word TOP Should Face Up
    GF0010204Courtesy of FORD MOTOR CO.
    CAUTION: The direct clutch friction plates are directional and must be installed with grooves pointing clockwise (I.D. to O.D.) and the word TOP facing up. Improper installation can result in transmission damage.
    NOTE: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.
  9. When installing new friction plates, the word TOP should face up. If reusing plates, grooves must be installed clockwise. Install the direct clutch disc pack.
    10. Fig 9: Identifying Direct Clutch Disc Pack
    GF0010218Courtesy of FORD MOTOR CO.
    NOTE: If new steel plates are being installed, make sure to use the correct steel plates. Use 2.14 mm (0.08 in) steel plates.
  10. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
    11. Fig 10: Identifying Direct Clutch Retaining Ring On Direct Clutch Disc Pack
    GF0010219Courtesy of FORD MOTOR CO.
    NOTE: The retaining ring is a select fit.
  11. Install the direct clutch pressure plate.
    1. Install the direct clutch pressure plate.
    2. Install the original direct clutch retaining ring on the direct clutch disc pack.
    12. Fig 11: Applying Air Pressure To Hole In Drum While Blocking Other Hole With A Finger
    GF0010213Courtesy of FORD MOTOR CO.
    WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 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: The direct clutch piston must apply with air pressure and release when the air is removed.
  12. Check the operation using compressed air.
    • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
    13. Fig 12: Checking Gap Between Direct Clutch Retaining Ring And Direct Clutch Pressure Plate (With Specifications)
    GF0010220Courtesy of FORD MOTOR CO.
  13. Push down on the direct clutch disc pack and check the gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.
    • If specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.
      DIRECT CLUTCH

      Part Number Thickness Diameter
      mm Inch mm Inch
      E860126-S 1.37 0.0539 130.1 5.122
      E860127-S 1.73 0.0681 130.1 5.122
      E860128-S 2.08 0.0819 130.1 5.122
      E860129-S 2.44 0.0961 130.1 5.122
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