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Overdrive/Direct Clutch Assembly: Assembly

  1. Install the direct clutch wave spring.
    2. Fig 1: Identifying Direct Clutch Wave Spring
    GF0031865Courtesy of FORD MOTOR CO.
  2. Lubricate the direct clutch pack in clean automatic transmission fluid.
    3. Fig 2: Identifying Direct Clutch Pack
    GF0031866Courtesy of FORD MOTOR CO.
  3. Install the direct clutch assembly and pressure plate.
    4. Fig 3: Identifying Direct Clutch Pressure Plate, Clutch Assembly & Wave Spring
    GF0031864Courtesy of FORD MOTOR CO.
  4. Install the direct clutch snap ring.
    5. Fig 4: Identifying Direct Clutch Snap Ring
    GF0031863Courtesy of FORD MOTOR CO.
  5. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
    6. Fig 5: Locating Direct Clutch Piston Seals
    GF0031862Courtesy of FORD MOTOR CO.
  6. Install the direct clutch piston return spring.
    7. Fig 6: Identifying Direct Clutch Piston Return Spring
    GF0031861Courtesy of FORD MOTOR CO.
  7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
    8. Fig 7: Identifying Direct Clutch Piston
    GF0031860Courtesy of FORD MOTOR CO.
  8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
    9. Fig 8: Identifying Rear Direct Clutch Piston Seal
    GF0031859Courtesy of FORD MOTOR CO.
    NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.
  9. Install the direct clutch cylinder and position the special tools on the cylinder.
    10. Fig 9: Installing Special Tools (307-584/2) & (307-589/2) On Direct Clutch Cylinder
    GF0031857Courtesy of FORD MOTOR CO.
    CAUTION: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab can be broken off.
  10. Using the special tools, compress the direct clutch piston return spring and install the snap ring.
    11. Fig 10: Compressing Direct Clutch Piston Return Spring & Removing Snap Ring
    GF0031858Courtesy of FORD MOTOR CO.
  11. Remove the special tools.
    12. Fig 11: Removing Special Tools (307-584/2, 307-589/2) & Direct Clutch Cylinder
    GF0031857Courtesy of FORD MOTOR CO.
  12. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
    13. Fig 12: Locating Overdrive Clutch Piston Outer Seals From Piston
    GF0031856Courtesy of FORD MOTOR CO.
  13. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
    14. Fig 13: Identifying Overdrive Clutch Piston Inner Sea
    GF0031855Courtesy of FORD MOTOR CO.
  14. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using the special tool.
    15. Fig 14: Pushing Overdrive Clutch Piston In Cylinder By Hand Using Special Tool (307-589/1)
    GF0031867Courtesy of FORD MOTOR CO.
    NOTE: Install the overdrive clutch piston return spring so that the holes are facing up.
  15. Install the overdrive clutch piston return spring.
    16. Fig 15: Identifying Overdrive Piston Return Spring
    GF0031852Courtesy of FORD MOTOR CO.
  16. Lubricate the seals on a new balance piston.
    17. Fig 16: Lubricating Seals On New Balance Piston
    GF0031868Courtesy of FORD MOTOR CO.
  17. Install a new balance piston.
    18. Fig 17: Identifying Balance Piston
    GF0031851Courtesy of FORD MOTOR CO.
  18. Install the special tools on the balance piston.
    19. Fig 18: Installing Special Tools (307-584/2) & (307-589/1) On Balance Piston
    GF0031849Courtesy of FORD MOTOR CO.
  19. Using the special tool, press the balance piston down and install the snap ring.
    20. Fig 19: Compressing Overdrive Piston Return Spring Using Special Tools (307-589/1)
    GF0031850Courtesy of FORD MOTOR CO.
  20. Remove the special tools from the balance piston.
    21. Fig 20: Removing Special Tools (307-584/2) & (307-589/1)
    GF0031849Courtesy of FORD MOTOR CO.
  21. Install the No. 2 rear sun gear thrust bearing.
    22. Fig 21: Identifying No. 2 Rear Sun Gear Thrust Bearing
    GF0031848Courtesy of FORD MOTOR CO.
  22. Install the overdrive clutch hub.
    23. Fig 22: Identifying Overdrive Clutch Hub
    GF0031869Courtesy of FORD MOTOR CO.
  23. Lubricate the overdrive clutch pack in clean automatic transmission fluid.
    24. Fig 23: Identifying Overdrive Clutch Pack
    GF0031870Courtesy of FORD MOTOR CO.
  24. Install the overdrive clutch pack assembly and the pressure plate.
    25. Fig 24: Identifying Overdrive Clutch Pack Assembly & Pressure Plate
    GF0031871Courtesy of FORD MOTOR CO.
  25. Install the overdrive clutch pack snap ring.
    26. Fig 25: Identifying Overdrive Clutch Snap Ring
    GF0031845Courtesy of FORD MOTOR CO.
  26. Position the overdrive/direct clutch assembly in the cover assembly, install a dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 1.13 mm (0.04 in) and 2.28 mm (0.08 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
    27. Fig 26: Installing Dial Indicator & Positioning Plunger On Overdrive Clutch Pressure Plate
    GF0031872Courtesy of FORD MOTOR CO.
  27. Position the plunger on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.98 mm (0.03 in) and 2.34 mm (0.08 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.
    28. Fig 27: Positioning Plunger On Direct Clutch Pressure Plate
    GF0031873Courtesy of FORD MOTOR CO.
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