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Overdrive/Direct Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean and inspect the O/D  /direct clutch assembly for damage or excessive wear and install new components as necessary.
  2. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.
    Fig 1: Locating Direct (3, 5, R) Clutch Piston Seals
    G06278884Courtesy of FORD MOTOR CO.
  3. Install the direct (3, 5, R) clutch wave spring.
    Fig 2: Locating Direct (3, 5, R) Clutch Wave Spring
    G06278885Courtesy of FORD MOTOR CO.
  4. Soak the direct (3, 5, R) clutch pack in clean automatic transmission fluid.
    Fig 3: Identifying Direct (3, 5, R) Clutch Pack
    G06278886Courtesy of FORD MOTOR CO.
  5. Install the direct (3, 5, R) clutch assembly and pressure plate.
    Fig 4: Locating Direct (3, 5, R) Clutch Pressure Plate, Clutch Pack And Wave Spring
    G06278887Courtesy of FORD MOTOR CO.
  6. Install the direct (3, 5, R) clutch snap ring.
    1. Using a suitable tool, compress the snap ring.
    2. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.
    3. Release the tension on the snap ring.
    Fig 5: Releasing Tension On Snap Ring
    G06278888Courtesy of FORD MOTOR CO.
  7. NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.

    Install the direct (3, 5, R) clutch piston return spring.

    Fig 6: Locating Direct (3, 5, R) Clutch Piston Return Spring
    G06278889Courtesy of FORD MOTOR CO.
  8. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.
    Fig 7: Locating Direct (3, 5, R) Clutch Piston
    G06278890Courtesy of FORD MOTOR CO.
  9. Install the direct (3, 5, R) clutch cylinder.
    Fig 8: Locating Direct (3, 5, R) Clutch Cylinder
    G06278891Courtesy of FORD MOTOR CO.
  10. NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.

    Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.

    1. Do not contact the O/D  /direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
    2. Install the snap ring.
    Fig 9: Identifying Balance Piston And Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G06278892Courtesy of FORD MOTOR CO.
  11. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 10: Identifying Balance Piston And Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G06278893Courtesy of FORD MOTOR CO.
  12. Install 2 new seals on the O/D  (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
    Fig 11: Locating Seals On O/D (4, 5, 6) Clutch Piston
    G06278894Courtesy of FORD MOTOR CO.
  13. Install a new O/D  (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.
    Fig 12: Locating O/D (4, 5, 6) Clutch Piston Inner Seal
    G06278895Courtesy of FORD MOTOR CO.
  14. Position the O/D  (4, 5, 6) clutch piston in place.
    Fig 13: Locating O/D (4, 5, 6) Clutch Piston
    G06278896Courtesy of FORD MOTOR CO.
  15. Using the Overdrive Clutch, Balance Piston, and Direct Clutch Compressor 307-589/1, install the O/D  (4, 5, 6) clutch piston into the O/D  /direct clutch assembly by hand.
    Fig 14: Identifying Overdrive Clutch, Balance Piston, And Direct Clutch Compressor 307-589/1
    G06278897Courtesy of FORD MOTOR CO.
  16. NOTE: Holes face up on the O/D  (4, 5, 6) clutch piston return spring.

    Install the O/D  (4, 5, 6) clutch piston return spring.

    Fig 15: Locating O/D (4, 5, 6) Clutch Piston Return Spring
    G06278898Courtesy of FORD MOTOR CO.
  17. Lubricate the seals on a new balance piston and position the piston in place.
    Fig 16: Locating Seals On Balance Piston
    G06278899Courtesy of FORD MOTOR CO.
  18. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
    Fig 17: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G06278900Courtesy of FORD MOTOR CO.
  19. Using a press, compress the O/D  (4, 5, 6) clutch return spring and install the snap ring.
    Fig 18: Compressing O/D (4, 5, 6) Clutch Return Spring
    G06278901Courtesy of FORD MOTOR CO.
  20. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 19: Identifying Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G06278902Courtesy of FORD MOTOR CO.
  21. Install the No. 2 thrust bearing.
    Fig 20: Locating No. 2 Thrust Bearing
    G06278903Courtesy of FORD MOTOR CO.
  22. Install the O/D  (4, 5, 6) clutch hub.
    Fig 21: Locating O/D (4, 5, 6) Clutch Hub
    G06278904Courtesy of FORD MOTOR CO.
  23. Soak the O/D  (4, 5, 6) clutch pack in clean automatic transmission fluid.
    Fig 22: Identifying O/D (4, 5, 6) Clutch Pack
    G06278905Courtesy of FORD MOTOR CO.
  24. Install the O/D  (4, 5, 6) clutch pack.
    Fig 23: Locating O/D (4, 5, 6) Clutch Pack
    G06278906Courtesy of FORD MOTOR CO.
  25. Install the O/D  (4, 5, 6) clutch pressure plate.
    Fig 24: Locating O/D (4, 5, 6) Clutch Pressure Plate
    G06278907Courtesy of FORD MOTOR CO.
  26. Install the O/D  (4, 5, 6) clutch snap ring.
    Fig 25: Locating O/D (4, 5, 6) Clutch Snap Ring
    G06278908Courtesy of FORD MOTOR CO.
  27. Install the input shaft.
    Fig 26: Locating Input Shaft
    G06278909Courtesy of FORD MOTOR CO.
  28. While holding the input shaft in place, install the snap ring.
    Fig 27: Locating Input Shaft Snap Ring
    G06278910Courtesy of FORD MOTOR CO.
  29. Position the O/D  /direct clutch assembly in the transaxle case, install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the O/D  (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the O/D  (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the O/D  (4, 5, 6) clutch pack for correct installation. If the O/D  (4, 5, 6) clutch pack is correctly installed, install a new O/D  (4, 5, 6) clutch pack.
    Fig 28: Applying Air Pressure To O/D (4, 5, 6) Clutch Piston Port
    G06278911Courtesy of FORD MOTOR CO.
  30. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator Gauge With Holding Fixture 100-002. The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.
    Fig 29: Applying Air Pressure To Direct (3, 5, R) Clutch Piston Port
    G06278912Courtesy of FORD MOTOR CO.
  31. Remove Dial Indicator Gauge With Holding Fixture 100-002, O/D  /direct clutch assembly and the No. 1 O/D  /direct clutch assembly thrust bearing.
Fig 30: Identifying Holding Fixture 100-002
G06278913Courtesy of FORD MOTOR CO.
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