E Clutch: Installation

All vehicles 

1. Install the new E clutch piston and balance dam inner seals. Lubricate the seals with petroleum jelly.

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2. NOTE: Clutch plate quantity is model dependant based on engine displacement.

   Soak the E clutch plates in clean transmission fluid. Install the E clutch assembly.

   1. Pressure plate (select fit)
   2. Friction plates

      Material: Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

   3. NOTE: Align the inner splines of the steel plates with the pressure plate internal splines.

      Steel plates

   4. Apply plate (2.9-3.0)

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3. Install the E clutch piston return spring.

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4. Install a new E clutch balance dam outer seal. Lubricate the seal with petroleum jelly.

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5. Install the E clutch balance dam in the new E clutch piston.
   1. E clutch balance dam
   2. E clutch piston

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6. Lubricate the new E clutch piston seal with petroleum jelly.

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7. Install the new E clutch piston and balance dam in the E clutch hub.

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8. NOTE: Do not compress the balance dam too far or damage to the E clutch hub can occur. Only compress the E clutch hub far enough to install the retainer.

   Using the special tool and a press, compress the E clutch balance dam and install the retainer. Use Special Service Tool: 307-741 Spring Compressor, F Clutch. Use the General Equipment: Hydraulic Press

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9. Assemble the special tools and position the E clutch assembly on the special tool. Use Special Service Tool: 307-662 Gauge, Clutch Pack Endplay, 307-003 (T57L-500-B) Holding Fixture, Transmission.

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10. Using the special tool, measure the E clutch clearance. Position the plunger so it rests on the top surface of the pressure plate. Zero the dial indicator. Pull up on the pressure plate and measure and record the clutch clearance in 3 different places. Average the 3 recorded clutch clearance measurements and compare the measurement to the clutch clearance chart in specifications to determine the correct size pressure plate. Install the correct E clutch pressure plate. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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11. Install the new input shaft O-ring seals.

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12. Install the input shaft in the E clutch and install the snap ring.

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13. Install the (T7) thrust bearing onto the E clutch with the tab locators up. Snap the bearing into place.

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14. NOTE: Align the outer splines on the friction plates.

    Install the input shaft and the E clutch into the No. 4 shell and sun gear.

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15. Install the lower rear No. 3 ring gear snap ring.

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16. Install the No. 3 ring gear and the snap ring. Align the snap ring gap 180 ° from the bottom snap ring gap.

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17. Install the (T6) thrust bearing onto the E clutch with the tab locators down. Snap the bearing into place.

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18. Install the special tool and adjust the special tool to align the bottom edge of the tool with the top edge of the bottom Teflon® seal groove. Use Special Service Tool: 307-787 F8 Seal Installer/Sizer Input Shaft.

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19. Install a new Teflon® seal on the special tool. Use Special Service Tool: 307-787 F8 Seal Installer/Sizer Input Shaft.

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20. Using the top half of the special tool, slide the Teflon® seal into the groove. Remove the special tools and repeat the steps for the other 4 Teflon® seals. Use Special Service Tool: 307-787 F8 Seal Installer/Sizer Input Shaft.

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21. Install the special tool to size the 5 Teflon® seals. Use Special Service Tool: 307-787 F8 Seal Installer/Sizer Input Shaft.

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22. Install the E clutch and input shaft assembly.

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23. Install the (T8) thrust bearing.

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24. 1. NOTE: Some early build transmissions are not equipped with laser applied ink marks.

       Inspect the No. 1 planetary carrier and the clutch and planetary container cylinder for laser applied ink marks.

    2. NOTE: If ink marks are present the marks must be aligned or a transmission vibration can occur.

       If ink marks are present align the marks and install the clutch and planetary container cylinder onto the No. 1 planetary carrier and install the snap ring. Make sure the snap ring is seated.

    3. Install the No. 1 planetary carrier snap ring. Make sure the snap ring is seated.

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25. Install the special tool to the top edge of the Teflon® seal groove. Use Special Service Tool: 307-804 F9 Seal Guide, Installer and Sizer.

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26. Install a new Teflon® seal on the special tool. Use Special Service Tool: 307-804 F9 Seal Guide, Installer and Sizer.

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27. Using the top half of the special tool, slide the Teflon® seal into the groove. Use Special Service Tool: 307-804 F9 Seal Guide, Installer and Sizer.

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28. Using the special tool, size the Teflon® seal. Use Special Service Tool: 307-804 F9 Seal Guide, Installer and Sizer.

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29. Install the special tool and adjust the special tool to align the bottom edge of the tool with the top edge of the bottom Teflon® seal groove. Use Special Service Tool: 307-796 F2 Seal Guide, Installer and Sizer.

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30. Install a new Teflon® seal on the special tool. Use Special Service Tool: 307-796 F2 Seal Guide, Installer and Sizer.

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31. Using the top half of the special tool, slide the Teflon® seal into the groove. Remove the special tools and repeat the steps for the other 4 Teflon® seals. Use Special Service Tool: 307-796 F2 Seal Guide, Installer and Sizer.

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32. Install the special tool to size the 5 Teflon® seals. Use Special Service Tool: 307-796 F2 Seal Guide, Installer and Sizer.

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33. Install the (T9) thrust bearing.

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34. Lubricate the output shaft bushing with petroleum jelly.

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35. Using the special tools and a floor crane, install the clutch and planetary assembly. Use Special Service Tool: 307-651 Bracket, Pump Remover/Installer, 307-651-02 Lift fixture adapter for 307-651.

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36. Install the new torque converter hub seal on the special tools. Use Special Service Tool: 205-1018 Installation Tube, 307-780 Converter Seal installer.

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37. Using the special tools, install the new torque converter hub seal. Use Special Service Tool: 205-1018 Installation Tube, 307-780 Converter Seal installer.

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38. Install the torque converter hub seal snap ring.

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39. Install the new front support-to-case seal with the seal color visible from the outside.

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40. Install the (T3) thrust bearing.

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41. Install the special tool. Use Special Service Tool: 307-790 Endplay Check Gauge.

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42. NOTE: The special tool height 0.50 in (12.7 mm) must be subtracted from the measurement to get the correct measurement A height.

    Using the special tools and a depth gauge, measure the distance from the top of the special tool to the top of the (T3) thrust bearing special tool in 2 different places. Average the measurements and subtract 0.50 in (12.7 mm). Record this as measurement A.

    1. Measure it
    2. Subtract it Use Special Service Tool: 307-661 Gauge, End Play, 307-661-01 Spacers/Plate, Clearance Gage.

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43. Using the special tool and a depth gauge, measure the distance from the top of the special tool to the transmission deck mating surface in 2 different places. Average the measurements. Record this measurement as measurement B. Use Special Service Tool: 307-661 Gauge, End Play.

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44. Using the special tool and a depth gauge, measure the distance from the top of the special tool to (T3) thrust bearing surface in 2 different places. Average the measurements. Record this as measurement C. Use Special Service Tool: 307-661 Gauge, End Play.

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45. NOTE: Recorded measurement A compensates for the differences in height of the special tool.

    Calculate the correct shim thickness. Subtract measurement C from measurement B and record this as measurement D. Subtract measurement D from measurement A to get the clearance between the front support and the (T3) thrust bearing. Using the Selective Fit Shim Charts in specifications, select the correct shim. Refer to: Specifications .

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46. Install the selective shim.

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47. NOTE: If replacing A clutch separating springs, all separating springs must be replaced as a matching set or damage can occur.
    NOTE: Clutch plate quantity is model dependant based on engine displacement.

    Soak the A clutch plates in clean transmission fluid. Install the A clutch assembly.

    1. Pressure plate
    2. Friction plates

       Material: Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A,) (MERCON® ULV)

    3. Separator springs
    4. Steel plates
    5. Apply plate (select fit)
    6. Wave spring

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48. Lubricate the transmission case-to-front support sealing surface, the Teflon seals and the front support O-ring with petroleum jelly.

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49. Install the special tool in the location shown. Use Special Service Tool: 307-797 Installer, Alignment Studs (3) and Alignment Pin (All 10R).

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50. Install the front support into the transmission case. Align the pump gear to the pump drive gear pocket area. Rotate the input shaft to align the one-way clutch splines with the No. 1 sun gear.

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51. 1. Install the special tool studs, washers and nuts in the location shown. Use Special Service Tool: 307-797 Installer, Alignment Studs (3) and Alignment Pin (All 10R).
    2. Tighten the special tool nuts evenly to seat the front support assembly to the transmission case.

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52. 1. With the special tools installed, hand tight the new front support bolts in a crisscross pattern.
    2. Remove the special tools and install the new front support bolts hand tight.

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53. Tighten the front support bolts in a crisscross pattern.

    Torque: 20 lb.ft (27 Nm)

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54. Using the special tool, install the torque converter. Use Special Service Tool: 307-091 Handle, Torque Converter.

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55. Install the special tool to hold the torque converter. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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56. Install the speed sensors.
    1. Intermediate Speed Sensor A (ISSA)
    2. TSS sensor
    3. Intermediate Speed Sensor B (ISSB)
    4. OSS sensor
    • Torque: 62 lb.in (7 Nm)

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57. Connect and lock the speed sensors.
    1. Intermediate Speed Sensor A (ISSA)
    2. TSS sensor
    3. Intermediate Speed Sensor B (ISSB)
    4. OSS sensor

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58. Install the transmission fluid pump and the bolts.

    Torque: 71 lb.in (8 Nm)

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59. Rotate the manual shaft to the park override position.

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60. NOTE: Only install 68 mm length bolts or the transmission clutch and planetary container can be damaged and result in transmission failure.

    Loosely install the main control valve body.

    1. NOTE: Be sure the main control-to-case seal is attached to the main control.
    2. Align the guide pins on the main control valve body with the alignment holes in the transmission case.
    3. Align the TR sensor with the park pawl lock valve.
    4. Loosely install the 68 mm length main control-to-transmission case bolts.
    Fig 1: Main Control Valve Body Bolts

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61. Tighten the bolts in the sequence shown.

    Torque: 89 lb.in (10 Nm)

    Fig 2: Main Control Valve Body Bolts Tightening Sequence

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62. Lock the main control main electrical connector.

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63. Install the filter seal in the pump.

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64. NOTE: If the bolts are installed in the wrong locations, transmission damage will occur.
    NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.

    Install the filter and the bolts in the correct locations.

    1. Short bolt 20 mm
    2. Long bolt 71 mm
    • Torque: 93 lb.in (10.5 Nm)

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    Auto-Start-Stop vehicles 

65. NOTE: If the transmission fluid was contaminated from a catastrophic failure, replace the transmission fluid auxiliary pump.

    Install the transmission fluid auxiliary pump and loosely install the bolts.

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66. Install the new transmission fluid auxiliary pump tube seal.

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67. Inspect the transmission fluid auxiliary pump tube O-ring.

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68. Install the transmission fluid auxiliary pump tube and loosely install the bolt.

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69. 1. Transmission fluid auxiliary pump bolts

       Torque: 97 lb.in (11 Nm)

    2. Transmission fluid auxiliary pump tube bolt

       Torque: 106 lb.in (12 Nm)

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70. Connect the transmission fluid auxiliary pump electrical connector.

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    All vehicles 

71. Clean and inspect the magnets and the retainers.

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72. NOTE: The transmission fluid pan gasket can be reused if not damaged.

    Align the tabs in the noted location and install the transmission fluid pan gasket.

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73. NOTE: Install the studbolts and bolts in the correct locations noted during removal.

    Install the transmission fluid pan and loosely install the studbolts and bolts.

    1. Tighten the studbolts in a crisscross pattern.

       Torque: 106 lb.in (12 Nm)

    2. Tighten the bolts in a crisscross pattern.

       Torque: 89 lb.in (10 Nm)

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74. Install the transmission fluid level indicator and plug assembly.

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75. Install the park override lever and the nut.

    Torque: 106 lb.in (12 Nm)

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76. Install the transmission assembly. Refer to: Transmission .