Intermediate Clutch Cylinder: Assembly

Clean and inspect the intermediate clutch cylinder. Install the intermediate clutch piston inner seal.

Fig 1: Locating Intermediate Clutch Piston Inner Seal
Courtesy of FORD MOTOR CO.

NOTE: Lightly coat all the seals and surfaces with petroleum jelly.

Fig 2: Locating Intermediate Clutch Piston

Courtesy of FORD MOTOR CO.

Install the intermediate clutch piston.
Install the intermediate clutch support and spring.

Fig 3: Locating Intermediate Clutch Spring
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 4: Installing Special Tool (307-319)
Courtesy of FORD MOTOR CO.
Using the special tool, install the intermediate clutch balance piston and seal assembly.

Fig 5: Using Special Tool (307-319) To Install Intermediate Clutch Balance Piston
Courtesy of FORD MOTOR CO.

CAUTION: Do not fully compress the intermediate clutch spring retainer.

Fig 6: Installing Snap Ring Using Special Tool (307-015)

Courtesy of FORD MOTOR CO.

Using the special tool, compress the intermediate clutch return spring and install the snap ring.
Install the intermediate clutch pack.
1. Install the cushion spring.
2. Install the clutch pack.
3. Install the pressure plate.
4. Install the snap ring.
  
  Fig 7: Identifying Cushion Spring, Clutch Pack, Pressure Plate And Snap Ring
  Courtesy of FORD MOTOR CO.
Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.

Fig 8: Measuring Clearance Between Retaining Ring And Clutch Cylinder Lip Special Tool (100-D002)
Courtesy of FORD MOTOR CO.

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