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Overdrive Clutch Assembly: Assembly

  1. Install the 2 scarf cut seals and the roller bearing.
    2. Fig 1: Locating Scarf Cut Seals And Roller Bearing
    GF0022775Courtesy of FORD MOTOR CO.
  2. Install a new outer O-ring seal on the overdrive clutch balance piston.
    3. Fig 2: Overdrive Clutch Balance Piston O-Ring Seal
    GF0022626Courtesy of FORD MOTOR CO.
  3. Install 2 new inner O-ring seals on the overdrive clutch apply piston.
    4. Fig 3: Overdrive Clutch Apply Piston O-Ring Seals
    GF0022627Courtesy of FORD MOTOR CO.
  4. Lubricate all the O-ring seals with clean automatic transmission fluid. Install the overdrive clutch apply piston into the drum with the O-ring seals and the 3 pads facing down toward the drum.
    5. Fig 4: Overdrive Clutch Apply Piston
    GF0022625Courtesy of FORD MOTOR CO.
    NOTE: The fingers on the return spring are facing down toward the piston.
  5. Install the overdrive clutch return spring.
    6. Fig 5: Overdrive Clutch Return Spring
    GF0022624Courtesy of FORD MOTOR CO.
    NOTE: The cone shape of the balance piston must face up when installed correctly.
  6. Lubricate all the O-ring seals with clean automatic transmission fluid. Install the overdrive clutch balance piston.
    7. Fig 6: Locating Overdrive Clutch Balance Piston
    GF0022774Courtesy of FORD MOTOR CO.
  7. Using the special tool, install a new overdrive clutch balance piston retaining ring.
    8. Fig 7: Identifying Overdrive Clutch Balance Piston Retaining Ring Using Special Tool (307-209) & A Press
    GF0022622Courtesy of FORD MOTOR CO.
  8. Install the new overdrive clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending with the pressure plate on the top.
  9. Install the overdrive clutch pack snap ring.
    10. Fig 8: Locating Overdrive Clutch Pack Snap Ring
    GF0022619Courtesy of FORD MOTOR CO.
    NOTE: All overdrive clutch plates, friction and steel are of a wave-type design.
  10. Install the overdrive clutch assembly into the special tool so the dial indicator fits into the opening of the snap ring.
    11. Fig 9: Installing Overdrive Clutch Assembly Into Special Tool (307-555)
    GF0022629Courtesy of FORD MOTOR CO.
  11. 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.
  12. Rotate the overdrive 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  
    13. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.
    • 5.4L engine - 0.5-0.9 mm (0.019-0.035 in).
  13. 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.
    14. NOTE: Inspect and install new thrust bearings as required.
  14. Install a new thrust bearing (T3).
    15. Fig 10: Locating Thrust Bearing (T3)
    GF0022773Courtesy of FORD MOTOR CO.
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