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Forward Clutch Assembly: Assembly

    NOTE: If a new planetary assembly is being installed, the new planetary assembly may not come with the snap ring installed.
    Fig 1: Locating Planetary Assembly Snap Ring
    G06127410Courtesy of FORD MOTOR CO.
  1. Install the planetary assembly snap ring, if necessary.
  2. Make sure the planetary snap ring is oriented as shown.
    Fig 2: Locating Planetary Snap Ring Oriented
    G06127411Courtesy of FORD MOTOR CO.
  3. Install the transmission fluid collector plate on the front planetary carrier.
    Fig 3: Locating Transmission Fluid Collector Plate
    G06127412Courtesy of FORD MOTOR CO.
  4. Install the T1 bearing onto the sun gear.
    Fig 4: Locating T1 Bearing Onto Sun Gear
    G06127413Courtesy of FORD MOTOR CO.
  5. Install the sun gear into the planet assembly with the T1 bearing facing down and the recessed part of the gear up.
    Fig 5: Locating Sun Gear In Planet Assembly
    G06127414Courtesy of FORD MOTOR CO.
  6. Install new O-ring seals onto the forward clutch piston.
    Fig 6: Locating O-Ring Seals And Forward Clutch Piston
    G06127415Courtesy of FORD MOTOR CO.
  7. Lightly coat the O-ring seals with clean transmission fluid and install the forward clutch piston into the forward clutch drum.
    Fig 7: Locating Forward Clutch Piston
    G06127416Courtesy of FORD MOTOR CO.
  8. Install the forward clutch return spring.
    Fig 8: Locating Forward Clutch Return Spring
    G06127417Courtesy of FORD MOTOR CO.
  9. Install a new O-ring seal onto the forward clutch balance dam. Lightly coat the O-ring seal with clean transmission fluid.
    Fig 9: Installing O-Ring Seal Onto Forward Clutch Balance Dam
    G06127418Courtesy of FORD MOTOR CO.
  10. Align the marks made during disassembly and install the balance dam into the forward clutch drum.
    Fig 10: Locating Aligning Marks Of Balance Dam And Forward Clutch Drum
    G06127402Courtesy of FORD MOTOR CO.
    11. NOTE: Prior to releasing the Clutch Spring Compressor 307-525, make sure that the snap ring is fully seated.
    Fig 11: Installing Retaining Ring
    G06127420Courtesy of FORD MOTOR CO.
  11. Using the Clutch Spring Compressor 307-525, slightly collapse the balance dam to install the retaining ring. Install the retaining ring.
    12. NOTE: Friction and steel plate quantity will vary based on engine displacement. For additional information, refer to the CLUTCH PLATE QUANTITY CHART .
    Fig 12: Identifying Forward Clutch Plates
    G06127421Courtesy of FORD MOTOR CO.
  12. Soak the new forward clutch plates in clean transmission fluid.
  13. Install the new forward clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates and install the pressure plate.
    Fig 13: Locating Pressure Plate
    G06127422Courtesy of FORD MOTOR CO.
  14. Install the forward clutch plate snap ring.
    Fig 14: Locating Forward Clutch Plate Snap Ring
    G06127423Courtesy of FORD MOTOR CO.
    15. NOTE: All forward clutch plates, friction and steel are of a wave-type design.
    Fig 15: Installing Forward Clutch Assembly Into Clutch End Play Gauge 307-555 And Dial Indicator Gauge With Holding Fixture 100-002
    G06127424Courtesy of FORD MOTOR CO.
  15. Install the forward clutch assembly into the Clutch End Play Gauge 307-555 and install the Dial Indicator Gauge with Holding Fixture 100-002 and position the plunger so it fits into the opening of the snap ring.
  16. With the Dial Indicator Gauge 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.
    Fig 16: Lifting Up On Steel Pressure Plate
    G06127425Courtesy of FORD MOTOR CO.
  17. Rotate the forward clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.
    READING DESCRIPTION CHART

    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  
    18. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.
    • 5.4L engine - 0.71-1.10 mm (0.028-0.043 in).
    • 4.6L engine - 0.71-1.10 mm (0.028-0.043 in).

    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.

  19. Install the sun gear and planetary gearset into the forward clutch drum. Make sure it snaps and locks in place.
    Fig 17: Locating Sun Gear And Planetary Gearset
    G06127426Courtesy of FORD MOTOR CO.
  20. Install the T2 thrust bearing.
    Fig 18: Locating T2 Thrust Bearing
    G06127427Courtesy of FORD MOTOR CO.
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