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Direct Clutch Cylinder: Disassembly

Fig 1: Identifying Direct Clutch Cylinder Assembly Components
G04005038Courtesy of FORD MOTOR CO.
  1. Remove the direct one-way clutch assembly.
    1. Remove the direct one-way clutch assembly.
    2. Remove the direct clutch cylinder thrust washer.
    Fig 2: Removing Direct One-Way Clutch Assembly
    G03957153Courtesy of FORD MOTOR CO.
  2. Disassemble, clean and inspect the direct one-way clutch, inner and outer races.
    Fig 3: Inspecting Direct One-Way Clutch, Inner And Outer Races
    G03957154Courtesy of FORD MOTOR CO.
    3. CAUTION: The circular depressions on the top of the nylon cage must be visible when installed on the inner race or the transaxle may be incorrectly assembled.
    NOTE: Outer race must rotate clockwise.
    Fig 4: Assembling One-Way Clutch
    G03957155Courtesy of FORD MOTOR CO.
  3. Assemble the one-way clutch.
  4. Using the special tool, remove the intermediate and direct clutch hub seal.
    Fig 5: Removing Intermediate And Direct Clutch Hub Seal
    G03957156Courtesy of FORD MOTOR CO.
    5. CAUTION: Check for wear on inner splines of friction plates. Install new plates if worn.
    Fig 6: Removing Intermediate Clutch Pack
    G04005043Courtesy of FORD MOTOR CO.
  5. Remove the intermediate clutch pack.
    1. Remove the snap ring.
    2. Remove the clutch pressure plate.
    3. Remove the clutch pack.
    6. CAUTION: Do not allow the special tool to bottom out on the piston.
    Fig 7: Compressing Clutch Spring
    G03957158Courtesy of FORD MOTOR CO.
  6. Using the special tool, compress the clutch spring and remove the snap ring.
  7. Remove the direct clutch return spring.
    Fig 8: Removing Direct Clutch Return Spring
    G03957159Courtesy of FORD MOTOR CO.
    8. NOTE: The seal is part of the piston and is serviced as an assembly. Make sure that the check ball in the piston moves freely.
    Fig 9: Removing Piston And Seal Assembly
    G03957160Courtesy of FORD MOTOR CO.
  8. Remove the piston and seal assembly.
  9. Separate the piston and seal assembly from the apply ring.
    Fig 10: Separating Piston And Seal Assembly From Apply Ring
    G03957161Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the inner piston seal.
    Fig 11: Removing Inner Piston Seal
    G03957162Courtesy of FORD MOTOR CO.
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