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Forward Clutch: Assembly

  1. Inspect the clutch components for damage or wear. Install new components as necessary.
    • 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.
    • Inspect the needle bearing and seal rings for damage.
    • Check clutch hub thrust surfaces for damage.
    • Check clutch plates for flatness and fit on the clutch hub serrations.
    2. NOTE: If the seals on the forward clutch piston show any signs of damage, a new forward clutch piston will need to be installed.
  2. Inspect the forward clutch piston and seals.
    3. Fig 1: Inspecting Forward Clutch Piston And Seals
    GF0015628Courtesy of FORD MOTOR CO.
  3. Inspect the forward clutch drum assembly.
    1. Inspect the forward clutch cylinder surfaces for scores or burrs.
    2. Inspect the forward clutch piston for scores or burrs.
    3. Verify the check ball is free to move in the piston.
    4. Fig 2: Inspecting Forward Clutch Piston For Scores Or Burrs
    GF0010229Courtesy of FORD MOTOR CO.
    NOTE: The special tool must be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.
  4. Install the special tool on the forward clutch piston.
    5. Fig 3: Identifying Special Tool (307-434)
    GF0015629Courtesy of FORD MOTOR CO.
    CAUTION: Care must be taken to prevent damage to the seals.
    NOTE: Lubricate the forward clutch piston inner and outer seal with clean automatic transmission fluid.
  5. Using the special tool, install the forward clutch piston assembly into the forward clutch cylinder.
    6. Fig 4: Identifying Special Tool (307-051)
    GF0015630Courtesy of FORD MOTOR CO.
  6. Install the forward clutch piston spring assembly.
    7. Fig 5: Locating Forward Clutch Piston Spring Assembly
    GF0015627Courtesy of FORD MOTOR CO.
    CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.
  7. Using the special tool, install the forward clutch piston spring retaining ring.
    8. Fig 6: Identifying Special Tool (307-015) And Forward Clutch Piston Spring Retaining Ring
    GF0010225Courtesy of FORD MOTOR CO.
    CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise, 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.
  8. If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
    9. Fig 7: Rotating Direct Clutch Disc Pack Counterclockwise
    GF0015631Courtesy of FORD MOTOR CO.
  9. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
    10. Fig 8: Locating Steel Clutch Plates And Friction Clutch Plates
    GF0015626Courtesy of FORD MOTOR CO.
    NOTE: The retaining ring is a select fit.
  10. Install the original selective retaining ring.
    1. Install the forward clutch pressure plate.
    2. Install the original selective retaining ring.
    11. Fig 9: Identifying Forward Clutch Pressure Plate & Original Selective Retaining Ring
    GF0010234Courtesy 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.
  11. Air check the forward clutch piston.
    1. Place the forward clutch cylinder with the forward clutch piston facing down.
    2. Install the transmission center support on the forward clutch cylinder.
    3. Apply air pressure to the left port of the center support.
    12. Fig 10: Identifying Forward Clutch Piston, Forward Clutch Cylinder And Left Port
    GF0010235Courtesy of FORD MOTOR CO.
  12. Check the forward clutch disc pack free play.
    1. Press down on the forward clutch disc pack.
    2. Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.
    3. If the clearance is not within specifications, install the correct size retaining ring.
      Part Number Thickness Diameter
      mm Inch mm Inch
      XW4Z-7D483-AB 1.73 0.0681 141.45 5.65
      XW4Z-7D483-AC 2.08 0.0819 141.45 5.65
      XW4Z-7D483-AD 2.44 0.0961 141.45 5.65
    13. Fig 11: Checking Gap Between Forward Clutch Retaining Ring And Forward Clutch Pressure Plate
    GF0015632Courtesy of FORD MOTOR CO.
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