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Direct Clutch Cylinder: Assembly

    NOTE: The lip on the seal must face toward the bottom of the clutch cylinder.
    Fig 1: Identifying Inner Piston Seal
    G04661437Courtesy of FORD MOTOR CO.
  1. Install the inner piston seal.
    2. NOTE: Make sure that the check ball is in place on the clutch piston. Lightly coat all the seals with petroleum jelly prior to installation.
    Fig 2: Installing Direct Clutch Piston And Seal Assembly Using Special Tool (307-168)
    G04661438Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the direct clutch piston and seal assembly making sure that it is fully seated.
  3. Install the apply ring. Make sure that it is fully seated on the clutch piston.
    Fig 3: Installing Ring
    G04661439Courtesy of FORD MOTOR CO.
    4. NOTE: The notch on the direct clutch return spring must line up with the check ball on the direct clutch piston.
    Fig 4: Locating Direct Clutch Return Spring
    G04661440Courtesy of FORD MOTOR CO.
  4. Install the direct clutch return spring.
    5. CAUTION: Do not allow the special tool to bottom out on the piston.
    Fig 5: Installing Snap Ring Using Special Tool (307-015)
    G04661441Courtesy of FORD MOTOR CO.
  5. Using the special tool, compress the clutch spring and install the snap ring.
    6. CAUTION: Check for wear on the inner splines of the friction plates. Install new plates if worn.
    NOTE: The clutch pressure plate must be installed with the chamfer edge facing up.
  6. Install the intermediate clutch pack.
    1. Install the intermediate clutch pack.
    2. Install the clutch pressure plate.
    3. Install the snap ring.
      Fig 6: Identifying Intermediate Clutch Pack, Clutch Pressure Plate And Snap Ring
      G04661442Courtesy of FORD MOTOR CO.
  7. Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.
    Fig 7: Measuring Clearance Between Retaining Ring And Clutch Cylinder Lip Using Special Tool (100-D002)
    G04661443Courtesy of FORD MOTOR CO.
  8. If the clearance is not within specification, selective retaining rings are available. Check the clearance after installing the correct selective retaining ring.
    SELECTIVE RETAINING RING SPECIFICATION

    mm Inch
    1.37-1.47 0.054-0.058
    1.65-1.75 0.065-0.069
    1.93-2.03 0.076-0.080
    2.21-2.31 0.087-0.091
    2.49-2.59 0.098-0.102
    2.77-2.87 0.109-0.113
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