Intermediate Brake and Direct Clutch Drum Assembly: Disassembly

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: Identifying Direct Clutch Pressure Plate & Clutch Retaining Ring

Courtesy of FORD MOTOR CO.

NOTE: The retaining ring is a select fit. See assembly procedure if installation of new ring or clutch pack is required.

Remove the direct clutch retaining ring and the direct clutch pressure plate.
1. Remove the direct clutch retaining ring.
2. Remove the direct clutch pressure plate.

Fig 2: Identifying Direct Clutch Disc Pack

Courtesy of FORD MOTOR CO.

NOTE: Clutch plates are directional. Note the direction of the grooves for installation.

Remove the direct clutch disc pack.
- Inspect and install new steel and friction plates if worn, damaged or overheated.
- Measure and record the thickness of the steel plates for assembly.

Fig 3: Identifying Special Tool (307-015) And Direct Clutch Piston Retaining Ring

Courtesy 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.

Using the special tool, remove the direct clutch piston retaining ring.
Relieve the direct clutch spring tension and remove the special tool.

Fig 4: Locating Direct Clutch Piston Spring Retainer

Courtesy of FORD MOTOR CO.

Remove the direct clutch piston spring retainer and the 20 direct clutch piston springs.
1. Lift the direct clutch piston spring retainer off the direct clutch piston springs.
2. Remove the direct clutch piston springs.

Fig 5: Removing Direct Clutch Piston From Intermediate Brake & Direct Clutch Drum Using Compressed Air

Courtesy 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.

Using compressed air, remove the direct clutch piston from the intermediate brake and direct clutch drum.
- Apply air pressure to the hole in the drum while blocking the other with a finger.

Fig 6: Identifying Direct Clutch Piston Inner & Outer Seal

Courtesy of FORD MOTOR CO.

Remove the direct clutch piston inner and outer seal.
1. Remove the direct clutch piston inner seal.
2. Remove the direct clutch piston outer seal.