Direct Clutch: Assembly

Soak the internal spline clutch plates in clean automatic transmission fluid.
Inspect the direct clutch piston bore surfaces for nicks or scratches. Install a new direct clutch piston if necessary.
Lubricate and install the direct clutch piston.

Fig 1: Locating Direct Clutch Piston Bore Surfaces
Courtesy of FORD MOTOR CO.
Install the direct clutch return spring.

Fig 2: Locating Direct Clutch Return Spring
Courtesy of FORD MOTOR CO.
Install the direct clutch balance piston.

Fig 3: Locating Direct Clutch Balance Piston
Courtesy of FORD MOTOR CO.
Using the special tool, install the selective snap ring.

Fig 4: Identifying Special Tool (307-209) Into Selective Snap Ring
Courtesy of FORD MOTOR CO.
Install the direct clutch pressure, friction and steel plates.
1. Install the plates.
2. Install the retaining ring.
  
  Fig 5: Identifying Retaining Ring And Plates
  Courtesy of FORD MOTOR CO.
Measure the clutch pack clearance.
1. Install the direct clutch on the transaxle end cover.
2. Install the special tool. Mount the dial indicator holding fixture on the transaxle end cover 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 6: Using Special Tool (100-002)
  Courtesy of FORD MOTOR CO.

Compare the direct clutch pack clearance to the specification (1.0-1.3 mm [0.0393-0.0511 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)