Low/Reverse Clutch Assembly: Assembly

Low/reverse piston 

1. Install new low/reverse outer piston O-ring seal.
   Fig 1: Locating Low/Reverse Outer Piston O-Ring Seal

   Courtesy of FORD MOTOR CO.
2. Install new low/reverse drum O-ring seal.
   Fig 2: Locating Low/Reverse Drum O-Ring Seal

   Courtesy of FORD MOTOR CO.
3. Lubricate the O-ring seal with clean transmission fluid. Align the alignment tab on the piston with the groove in the center support and install the low/reverse piston.
   Fig 3: Locating Alignment Tab On Piston With Groove

   Courtesy of FORD MOTOR CO.
4. Install the low/reverse clutch return spring.
   Fig 4: Locating Low/Reverse Clutch Return Spring

   Courtesy of FORD MOTOR CO.
5. Install a new low/reverse clutch return spring retainer. Align the alignment tab on the retainer with the groove in the center support and install the low/reverse piston return spring retainer.
   Fig 5: Locating Low/Reverse Clutch Return Spring Retainer

   Courtesy of FORD MOTOR CO.
6. Using the Clutch Spring Compressor, compress the low/reverse clutch return spring and install the retaining ring.
   Fig 6: Compressing Low/Reverse Clutch Return Spring

   Courtesy of FORD MOTOR CO.

   Low/reverse clutch stackup 

NOTE: All low/reverse clutch plates, friction and steel are of a wave-type design.
Fig 7: Installing D-Clutch Measurement Gauge Into Case
Courtesy of FORD MOTOR CO.
7. Install the D-Clutch Measurement Gauge into the case.
8. With the D-Clutch Measurement Gauge positioned in the case, use the Depth Micrometer to measure the case stop depth.

   Description	Reading
   Measure the distance from the top of the upper gauge bar to the top of the lower gauge bar. Record this reading as the case measurement. Record as reading A.

   Fig 8: Measuring Case Stop Depth

   Courtesy of FORD MOTOR CO.
9. Measure the clutch pack height.

   Description

   Reading

   Place the low/reverse clutch pack on the Clutch End Play Gauge with the wave spring down and the pressure plate on top. Using the Dial Indicator Gauge with Holding Fixture, place the plunger on the pressure plate. Slide the clutch to the side so the plunger of the Dial Indicator is touching the gauge plate of the Clutch End Play Gauge. Zero out the Dial Indicator Gauge. Carefully lift the plunger enough to slide the clutch pack under the plunger to take a reading. Record this reading. Rotate the clutch pack 180 degrees and take a second reading. Add the first and second readings together and divide the total by 2. Record this reading as B.

   Fig 9: Measuring Clutch Pack Height

   Courtesy of FORD MOTOR CO.
10. Using the Depth Micrometer, measure the piston to center support shoulder height.

    Description	Reading
    Measure the piston to center support shoulder height. Record this measurement. Rotate the center support 180 degrees and record this measurement. Add the first and the second measurements, then divide by 2. Record this as reading C.

    Fig 10: Measuring Piston To Center Support Shoulder Height

    Courtesy of FORD MOTOR CO.
11. Calculate the end clearance.

    Description	Reading
    Subtract B and C from A to determine end clearance
    Total C measurement
    End clearance specification	1.0-1.6 mm (0.039-0.062 in)

    Compare the end clearance to the specification. If the end clearance is out of specification, select the next thinner or thicker plate as required and repeat Steps  10,  11 and  12.