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Home >> Ford >> 2006 >> Focus ZX3 SES, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Disassembly And Assembly Of Subassemblies >> Forward Clutch >> Assembly
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Forward Clutch: Assembly

  1. Soak the internal spline clutch plates in clean automatic transmission fluid.
  2. Inspect the forward clutch piston bore surfaces for nicks or scratches. Install a new balance piston if necessary.
  3. Lubricate and install the forward clutch piston assembly.
    Fig 1: Locating Clutch Piston Assembly
    G04652911Courtesy of FORD MOTOR CO.
  4. Install the forward piston return spring.
    Fig 2: Locating Piston Return Spring
    G04652912Courtesy of FORD MOTOR CO.
  5. Lubricate and install the forward clutch balance piston.
    Fig 3: Locating Clutch Balance Piston
    G04652913Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the forward clutch assembly in a suitable press.
    Fig 4: Identifying Special Tool (307-209) On Clutch Assembly
    G04652914Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the forward clutch balance piston snap ring.
    Fig 5: Identifying Special Tool (307-209) Into Clutch Balance Piston Snap Ring
    G04652915Courtesy of FORD MOTOR CO.
  8. Install the forward clutch pressure, friction and steel plates.
    1. Install the plates.
    2. Install the retaining ring.
      Fig 6: Identifying Retaining Ring And Plates
      G04652916Courtesy of FORD MOTOR CO.
  9. Measure the clutch pack clearance.
    1. Install the forward clutch on the pump assembly.
    2. Install the special tool. Mount the dial indicator holding fixture on the pump assembly and position the dial indicator plunger on the pressure plate.
    3. Using a suitable tool, lift up on both sides of the clutch pack and measure and record the clutch pack clearance on the dial indicator in 3 different areas. Average the measurements.
      Fig 7: Using Special Tool (100-002)
      G04652917Courtesy of FORD MOTOR CO.
  10. Compare the forward clutch pack clearance to the specification (1.5-1.8 mm [0.0590-0.0708] in). If the clutch pack clearance is not within specification, select and install the correct size retaining ring to obtain the specified clearance.
    COMPONENTS THICKNESS REFERENCE

    Part Number Thickness
    - 1.15-1.25 mm (0.0452-0.0492 in)
    - 1.35-1.45 mm (0.0531-0.0570 in)
    - 1.55-1.65 mm (0.0610-0.0649 in)
    - 1.75-1.85 mm (0.0688-0.0728 in)
    - 1.95-2.05 mm (0.0767-0.0807 in)
    - 2.15-2.25 mm (0.0846-0.0885 in)
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