Direct Clutch Drum Assembly: Assembly

Inspect the clutch components for damage or wear. Install new components as necessary.
- Inspect the drum surface for damage.
- Inspect the clutch piston bore and piston.
- Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
- Inspect the clutch plates for damage.
- Inspect the clutch springs.

CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

NOTE: Use new seals to help prevent seal failures.

Install the new direct clutch piston inner seal and the direct clutch piston outer seal.

Fig 1: Locating Direct Clutch Piston Inner Seal And Direct Clutch Piston Outer Seal

Courtesy of FORD MOTOR CO.

Verify the check ball is free to move.

Fig 2: Locating Check Ball

Courtesy of FORD MOTOR CO.

CAUTION: Care must be taken to prevent damage to the seals during installation.

Using the special tool, install the direct clutch piston.
- Lubricate the seals with transmission fluid before installing.

Fig 3: Locating Direct Clutch Piston

Courtesy of FORD MOTOR CO.

Install the direct clutch piston springs and the retainer.

Fig 4: Locating Direct Clutch Piston Springs And Retainer

Courtesy of FORD MOTOR CO.

WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.

CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.

Using the special tool, install the direct clutch piston retaining ring.

Fig 5: Identifying Special Tool (307-015) And Direct Clutch Piston Retaining Ring

Courtesy of FORD MOTOR CO.

CAUTION: The direct clutch friction plates are directional and must be installed correctly. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates, otherwise transmission damage can occur.

CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly, otherwise transmission damage can occur.

When installing friction plates, alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates. Install the direct clutch disc pack.

Fig 6: Alternating Direct Clutch Disc Pack Plates

Courtesy of FORD MOTOR CO.

Install the friction plates alternating the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates starting with an externally splined (counterclockwise) clutch plate.

Fig 7: Locating Direct Clutch Disc Pack

Courtesy of FORD MOTOR CO.

NOTE: The retaining ring is a select fit.

Install the direct clutch pressure plate using the original direct clutch retaining ring.

Fig 8: Identifying Direct Clutch Pressure Plate And Direct Clutch Retaining Ring

Courtesy of FORD MOTOR CO.

WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 psi) and always wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to follow this instruction may result in serious personal injury.

Air check the assembly.
- Apply air pressure to the hole in the drum while blocking the other hole with a finger.

Fig 9: Locating Drum Air Pressure Apply Hole

Courtesy of FORD MOTOR CO.

Push down on the direct clutch disc pack and check the gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.

If the specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.

DIRECT CLUTCH

Part Number	Thickness		Diameter
Part Number	mm	Inch	mm	Inch
E860126-S	1.37	0.0539	130.1	5.122
E860127-S	1.73	0.0681	130.1	5.122
E860128-S	2.08	0.0819	130.1	5.122
E860129-S	2.44	0.0961	130.1	5.122

Fig 10: Checking Gap Between Direct Clutch Retaining Ring And Direct Clutch Pressure Plate (With Specifications)

Courtesy of FORD MOTOR CO.