Intermediate Clutch Cylinder: Assembly

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

Fig 1: Intermediate Clutch Piston Inner Seal

Courtesy of FORD MOTOR CO.

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

Install the intermediate clutch piston.

Fig 2: Intermediate Clutch Piston

Courtesy of FORD MOTOR CO.

Install the intermediate clutch support and spring.

Fig 3: Intermediate Clutch Return Spring

Courtesy of FORD MOTOR CO.

Install the special tool.

Fig 4: Identifying Special Tool (307-319)

Courtesy of FORD MOTOR CO.

Using the special tool, install the intermediate clutch balance piston and seal assembly.

Fig 5: Installing Intermediate Clutch Balance Piston And Seal Assembly Using Special Tool (307-319)

Courtesy of FORD MOTOR CO.

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

Using the special tool, compress the intermediate clutch return spring and install the snap ring.

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

Courtesy of FORD MOTOR CO.

Install the intermediate clutch pack.
1. Install the wave spring.
2. Install the clutch pack.
3. Install the pressure plate.
4. Install the snap ring.

Fig 7: Identifying Intermediate Clutch Pack

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 (With Specifications)

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

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