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Forward Clutch: Assembly

  1. Inspect the clutch components for damage or wear. Install new components as necessary.
    • 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.
    • Inspect the needle bearing and seal rings for damage.
    • Check clutch hub thrust surfaces for damage.
    • Check clutch plates for flatness and fit on the clutch hub serrations.
    2. NOTE: If the seals on the forward clutch piston show any signs of damage, the forward clutch piston will need to be replaced.
    Fig 1: Inspecting Forward Clutch Piston And Seals
    G03949030Courtesy of FORD MOTOR CO.
  2. Inspect the forward clutch piston and seals.
  3. Inspect the forward clutch drum assembly.
    1. Inspect the forward clutch cylinder surfaces for scores or burrs.
    2. Inspect forward clutch piston for scores or burrs.
    3. Verify the check ball is free to move in the piston.
      Fig 2: Inspecting Forward Clutch Drum Assembly
      G03949031Courtesy of FORD MOTOR CO.
    4. NOTE: The special tool must be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.
    Fig 3: Installing Special Tool On Forward Clutch Piston
    G03949032Courtesy of FORD MOTOR CO.
  4. Install the special tool on the forward clutch piston.
    5. CAUTION: Care must be taken to prevent damage to the seals.
    NOTE: Lubricate the forward clutch piston inner and outer seal with clean automatic transmission fluid.
    Fig 4: Installing Forward Clutch Piston Assembly Into Forward Clutch Cylinder
    G03949033Courtesy of FORD MOTOR CO.
  5. Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.
  6. Install the forward clutch piston spring assembly.
    Fig 5: Installing Forward Clutch Piston Spring Assembly
    G03949028Courtesy of FORD MOTOR CO.
    7. CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
    Fig 6: Installing Forward Clutch Piston Spring Retaining Ring
    G03949027Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the forward clutch piston spring retaining ring.
    8. CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise.
    CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.
    Fig 7: Installing Direct Clutch Disc Pack
    G03949036Courtesy of FORD MOTOR CO.
  8. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
  9. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
    Fig 8: Identifying Steel Clutch Plates And Friction Clutch Plates
    G03997558Courtesy of FORD MOTOR CO.
    10. CAUTION: The retaining ring is a select fit.
  10. Install the original selective retaining ring.
    1. Install the forward clutch pressure plate.
    2. Install the original selective retaining ring.
      Fig 9: Installing Original Selective Retaining Ring
      G03949038Courtesy of FORD MOTOR CO.
    11. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.
  11. Air check the forward clutch piston.
    1. Place the forward clutch cylinder with forward clutch piston facing down.
    2. Install the transmission center support on the forward clutch cylinder.
    3. Apply air pressure to the left port of the center support.
      Fig 10: Applying Air Pressure To Left Port Of Center Support
      G03949039Courtesy of FORD MOTOR CO.
  12. Check forward clutch disc pack free play.
    1. Press down on forward clutch disc pack.
    2. Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.
      • If the clearance is not within specifications, install the correct size retaining ring.
        FORWARD CLUTCH DISC PACK FREE PLAY SPECIFICATIONS

        Part Number Thickness Diameter
        mm in mm in
        XW4Z-7D483-AB 1.73 0.0681 141.45 5.65 in
        XW4Z-7D483-AC 2.08 0.0819 141.45 5.65 in
        XW4Z-7D483-AD 2.44 0.0961 141.45 5.65 in
        Fig 11: Checking Gap Between Forward Clutch Retaining Ring And Forward Clutch Pressure Plate
        G03949040Courtesy of FORD MOTOR CO.
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