Forward Clutch Assembly: Assembly

NOTE: If a new planetary assembly is being installed, the new planetary assembly may not come with the snap ring installed.

Install the planetary assembly snap ring, if necessary.

Fig 1: Locating Planetary Assembly Snap Ring

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Make sure the planetary snap ring is oriented as shown.

Fig 2: Locating Planetary Snap Ring

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Install the T1 bearing onto the sun gear.

Fig 3: Sun Gear Bearing

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Install the sun gear into the planet assembly with the T1 bearing facing down and the recessed part of the gear up.

Fig 4: Locating Sun Gear

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Install new O-ring seals onto the forward clutch piston.

Fig 5: Inner & Outer Piston O-Ring Seals

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Lightly coat the O-ring seals with clean transmission fluid and install the forward clutch piston into the forward clutch drum.

Fig 6: Forward Clutch Piston

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Install the forward clutch return spring.

Fig 7: Forward Clutch Return Spring

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Install a new O-ring seal onto the forward clutch balance dam. Lightly coat the O-ring seal with clean transmission fluid.

Fig 8: Balance Dam O-Ring Seal

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Align the marks made during disassembly and install the balance dam into the forward clutch drum.

Fig 9: Locating Balance Dam

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NOTE: Prior to releasing the special tool, make sure that the snap ring is fully seated.

Using the special tool, slightly collapse the balance dam to install the retaining ring. Install the retaining ring.

Fig 10: Balance Dam Retaining Ring

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Install the new forward clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending up with the pressure plate.

Fig 11: Locating Forward Clutch Steel And Friction Plates

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Install the forward clutch plate snap ring.

Fig 12: Locating Forward Clutch Pack Snap Ring

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NOTE: All forward clutch plates, friction and steel are of a wave-type design.

Install the forward clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.

Fig 13: Identifying Special Tool

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With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.

Rotate the forward clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.

Description	Reading
Reading A
Reading B
Add reading A to reading B for a total end clearance
Divide the total reading by 2 for an average end clearance

NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.

5.4L engine - 0.71-1.10 mm (0.028-0.043 in).

If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
Install the sun gear and planetary gearset into the forward clutch drum. Make sure it snaps and locks in place.

Fig 14: Locating Sun Gear Into Forward Clutch Drum

Courtesy of FORD MOTOR CO.