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Direct Clutch Assembly: Assembly

  1. Install a new inner and outer O-ring seal on the apply piston.
    2. Fig 1: Locating Inner And Outer O-Ring Seal
    GF0022645Courtesy of FORD MOTOR CO.
  2. Install a new outer O-ring seal on the balance piston.
    3. Fig 2: Locating Outer O-Ring Seal
    GF0022644Courtesy of FORD MOTOR CO.
  3. Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.
    4. Fig 3: Direct Clutch Piston
    GF0022643Courtesy of FORD MOTOR CO.
  4. Lightly coat the O-ring seals in clean transmission fluid and install the apply piston into the direct clutch balance piston.
    5. Fig 4: Locating Baffle Plate
    GF0022642Courtesy of FORD MOTOR CO.
  5. Slightly press down on the balance piston and install a new snap ring.
    6. Fig 5: Locating Snap Ring
    GF0022641Courtesy of FORD MOTOR CO.
  6. Install the direct clutch return spring.
    7. Fig 6: Identifying Direct Clutch Return Spring
    GF0022640Courtesy of FORD MOTOR CO.
    NOTE: When installing the washer, the stepped edge must face upward.
  7. Install the direct clutch return spring washer.
    8. Fig 7: Locating Direct Clutch Return Spring Washer
    GF0022639Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    9. Fig 8: Identifying Special Tool (307-552)
    GF0022638Courtesy of FORD MOTOR CO.
  9. Using the special tool, install the direct clutch return spring retainer.
    10. Fig 9: Identifying Direct Clutch Return Spring Retainer Using Special Tools (307-015, 307-552)
    GF0022637Courtesy of FORD MOTOR CO.
  10. Install the new direct clutch plates, starting with the wave spring then a steel plate and alternating between steel and friction plates, and ending with the pressure plate on the top.
  11. Install the direct clutch snap ring.
    12. Fig 10: Locating Direct Clutch Snap Ring
    GF0022779Courtesy of FORD MOTOR CO.
    NOTE: Inspect and install new thrust bearings as required.
  12. Install a new thrust bearing (T5).
    13. Fig 11: Locating Thrust Bearing (T5)
    GF0022778Courtesy of FORD MOTOR CO.
    NOTE: All direct clutch plates, friction and steel are of a wave-type design.
  13. Install the direct clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.
    14. Fig 12: Installing Direct Clutch Assembly Into Special Tool (307-555)
    GF0022646Courtesy of FORD MOTOR CO.
  14. 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.
  15. Rotate the direct 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  
    16. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.
    • 5.4L engine - 0.5-1.3 mm (0.019-0.051 in).
  16. 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.
  17. Install 2 new scarf cut seals and the roller bearing.
    18. Fig 13: Locating Scarf Cut Seals And Roller Bearing
    GF0022777Courtesy of FORD MOTOR CO.
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