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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 128 (Automatic Transmission) >> Disassembly And Assembly Of Subassemblies >> Output Shaft And Direct Clutch Cylinder >> Assembly

Output Shaft And Direct Clutch Cylinder: Assembly

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Lubricate the direct clutch piston inner seal and seal protector with petroleum jelly.
  1. Using the special tool, install the inner piston seal.
    • Install the seal with sealing lip facing down.
    2. Fig 1: Installing Inner Piston Seal Using Special Tool
    GF0003676Courtesy of FORD MOTOR CO.
  2. Install the clutch piston outer seal so that when the piston is installed, the sealing lip points toward the bottom of the cylinder.
    3. Fig 2: Locating Clutch Piston Outer Seal
    GF0003675Courtesy of FORD MOTOR CO.
    NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.
  3. Using the special tool, install the direct clutch piston.
    4. Fig 3: Installing Clutch Piston Using Special Tool
    GF0003677Courtesy of FORD MOTOR CO.
  4. Install the piston return spring and retainer assembly.
  5. Using the special tool, compress the piston return spring and install the retaining ring.
    6. Fig 4: Compressing Piston Return Spring Using Special Tool
    GF0003672Courtesy of FORD MOTOR CO.
    NOTE: Before assembly, soak new clutch discs in clean transmission fluid.
  6. Install the direct clutch pack.
    1. Install the direct clutch plates.
      • Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
    2. Install the direct clutch pressure plate.
    3. Install the clutch pack retaining ring.
    7. Fig 5: Identifying Direct Clutch Pack Retaining Ring And Direct Clutch Pressure Plate
    GF0003678Courtesy of FORD MOTOR CO.
  7. Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate.
    • If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.
      SELECTIVE RETAINING RING

      Specification
      1.270-1.372 mm (0.050-0.054 in)
      1.625-1.727 mm (0.064-0.068 in)
      1.981-2.083 mm (0.078-0.082 in)
      2.337-2.438 mm (0.092-0.096 in)
    8. Fig 6: Checking Clearance Between Clutch Pack Selective Retaining Ring And Pressure Plate
    GF0012385Courtesy of FORD MOTOR CO.
  8. Install the direct clutch hub.
    1. Install the No. 7 direct clutch inner support with step side down.
    2. Install the No. 7 direct clutch bearing with the black marking up.
    3. Install the direct clutch hub.
    9. Fig 7: Locating Direct Clutch Bearing And Direct Clutch Hub
    GF0003680Courtesy of FORD MOTOR CO.
    NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.
  9. Using the special tool install the first direct clutch seal ring.
    10. Fig 8: Installing First Direct Clutch Seal Ring Using Special Tools
    GF0003681Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the second direct clutch seal ring.
    11. Fig 9: Installing Second Direct Clutch Seal Ring Using Special Tools
    GF0003682Courtesy of FORD MOTOR CO.
  11. After both new seals have been installed, use the special tool to size the seals.
    12. Fig 10: Identifying Special Tool
    GF0003683Courtesy of FORD MOTOR CO.
  12. Install the output shaft hub.
    • Position the output shaft hub.
    • Install the retaining ring.
    13. Fig 11: Installing Output Shaft Hub
    GF0003684Courtesy of FORD MOTOR CO.
  13. Install the 3 output shaft seal rings.
    14. Fig 12: Installing Three Output Shaft Seal Rings
    GF0003685Courtesy of FORD MOTOR CO.
    NOTE: The No. 8 bearing has a black oxide coating on the face. Install the No. 8 bearing with the black oxide coating facing up.
  14. Install the No. 8 needle bearing on the direct clutch cylinder.
    15. Fig 13: Locating No. 8 Needle Bearing On Direct Clutch Cylinder
    GF0003686Courtesy of FORD MOTOR CO.
    NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.
  15. Assemble the direct clutch on the output shaft.
    16. Fig 14: Identifying Direct Clutch Assembly On Output Shaft
    GF0003687Courtesy of FORD MOTOR CO.
    CAUTION: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear.
  16. Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.
    17. Fig 15: Locating Ring Gear Snap Ring
    GF0003665Courtesy of FORD MOTOR CO.
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