LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2006 >> Freestar Base >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Disassembly And Assembly Of Subassemblies >> Direct Clutch Cylinder >> Disassembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Direct Clutch Cylinder: Disassembly

  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 1: Identifying Direct One-Way Clutch Assembly And Direct Clutch Cylinder Thrust Washer
      G04661427Courtesy of FORD MOTOR CO.
  2. Disassemble, clean and inspect the direct one-way clutch, inner and outer races.
    Fig 2: Locating One-Way Clutch, Inner And Outer Races
    G04661428Courtesy 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 3: Locating One-Way Clutch
    G04661429Courtesy of FORD MOTOR CO.
  3. Assemble the one-way clutch.
  4. Using the special tool, remove the intermediate and direct clutch hub seal.
    Fig 4: Removing Intermediate And Direct Clutch Hub Seal Using Special Tool (100-010)
    G04661430Courtesy of FORD MOTOR CO.
    5. CAUTION: Check for wear on inner splines of friction plates. Install new plates if worn.
  5. Remove the intermediate clutch pack.
    1. Remove the snap ring.
    2. Remove the clutch pressure plate.
    3. Remove the clutch pack.
      Fig 5: Identifying Snap Ring, Clutch Pressure Plate And Clutch Pack
      G04661431Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not allow the special tool to bottom out on the piston.
    Fig 6: Removing Snap Ring Using Special Tool (307-015)
    G04661432Courtesy 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 7: Locating Clutch Return Spring
    G04661433Courtesy 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 8: Locating Piston And Seal Assembly
    G04661434Courtesy of FORD MOTOR CO.
  8. Remove the piston and seal assembly.
  9. Separate the piston and seal assembly from the apply ring.
    Fig 9: Separating Piston And Seal Assembly
    G04661435Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the inner piston seal.
    Fig 10: Removing Inner Piston Seal Using Special Tool (100-010)
    G04661436Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals