Direct Clutch Drum Assembly: Assembly

Inspect the clutch components for damage or wear. Install new components as necessary.
- Inspect the drum surface for damage.
- Inspect the clutch piston bore, and piston.
- Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
- Inspect the clutch plates for damage.
- Inspect the clutch springs.

CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

NOTE: Use new seals to help prevent seal failures.

Fig 1: Installing New Direct Clutch Piston Inner Seal And Direct Clutch Piston Outer Seal

Courtesy of FORD MOTOR CO.

Install the new direct clutch piston inner seal and the direct clutch piston outer seal.
Verify the check ball is free to move.

Fig 2: Verifying Check Ball Is Free To Move
Courtesy of FORD MOTOR CO.

CAUTION: Care must be taken to prevent damage to the seals during installation.

Using the special tool, install the direct clutch piston.
- Lubricate the seals with transmission fluid before installing.
  
  Fig 3: Installing Direct Clutch Piston
  Courtesy of FORD MOTOR CO.
Install the direct clutch piston springs and the retainer.

Fig 4: Installing Direct Clutch Piston Springs And Retainer
Courtesy of FORD MOTOR CO.

WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.

CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.

Fig 5: Installing Direct Clutch Piston Retaining Ring

Courtesy of FORD MOTOR CO.

Using the special tool, install the direct clutch piston retaining ring.

CAUTION: The direct clutch friction plates are directional and must be installed correctly. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates.

CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.

Fig 6: Installing Direct Clutch Disc Pack

Courtesy of FORD MOTOR CO.

When installing friction plates, alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates. Install the direct clutch disc pack.
Install the friction plates alternating the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates starting with an externally splined (counterclockwise) clutch plate.

Fig 7: Installing Friction Plates
Courtesy of FORD MOTOR CO.

CAUTION: The retaining ring is a select fit.

Fig 8: Installing Direct Clutch Pressure Plate Using Original Direct Clutch Retaining Ring

Courtesy of FORD MOTOR CO.

Install the direct clutch pressure plate using the original direct clutch retaining ring.

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.

Air check the assembly.
- Apply air pressure to the hole in the drum while blocking the other hole with a finger.
  
  Fig 9: Identifying Hole in Drum
  Courtesy of FORD MOTOR CO.

Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.

If specifications do not match use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.

DIRECT CLUTCH SPECIFICATIONS

Part Number	Thickness		Diameter
Part Number	mm	In	mm	In
E860126-S	1.37	0.0539	130.1	5.122
E860127-S	1.73	0.0681	130.1	5.122
E860128-S	2.08	0.0819	130.1	5.122
E860129-S	2.44	0.0961	130.1	5.122

Fig 10: Checking Gap Between Direct Clutch Retaining Ring And Direct Clutch Pressure Plate

Courtesy of FORD MOTOR CO.