Intermediate Clutch Cylinder: Assembly: Notes

WARNING: This page is about a different car, the 2003 Ford Windstar. However, it is still accessible from the selected car via links, so may be relevant.

Clean and inspect the intermediate clutch cylinder. Install the intermediate clutch piston inner seal.

Fig 1: Installing Intermediate Clutch Piston Inner Seal
Courtesy of FORD MOTOR CO.

NOTE: Lightly coat all the seals and surfaces with petroleum jelly.

Fig 2: Installing Intermediate Clutch Piston

Courtesy of FORD MOTOR CO.

Install the intermediate clutch piston.
Install the intermediate clutch support and spring.

Fig 3: Installing Intermediate Clutch Support And Spring
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 4: Installing Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, install the intermediate clutch balance piston and seal assembly.

Fig 5: Installing Intermediate Clutch Balance Piston And Seal Assembly
Courtesy of FORD MOTOR CO.

CAUTION: Do not fully compress the intermediate clutch spring retainer.

Fig 6: Installing Snap Ring

Courtesy of FORD MOTOR CO.

Using the special tool, compress the intermediate clutch return spring and install the snap ring.
Install the intermediate clutch pack.
1. Install the clutch pack.
2. Install the pressure plate.
3. Install the snap ring.
  
  Fig 7: Installing Intermediate Clutch Pack
  Courtesy of FORD MOTOR CO.
Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.

Fig 8: Measuring Clearance Between Retaining Ring And Clutch Cylinder Lip
Courtesy of FORD MOTOR CO.
If the clearance is not within specification, selective retaining rings are available. Check the clearance after installing the correct selective retaining ring.