Intermediate Clutch Assembly: Assembly

Install new inner and outer intermediate clutch piston O-ring seals.

Fig 1: Locating Inner And Outer Intermediate Clutch Piston O-Ring Seals
Courtesy of FORD MOTOR CO.
Lightly coat the O-ring seals in clean automatic transmission fluid and install the intermediate clutch piston.

Fig 2: Locating Intermediate Clutch Piston
Courtesy of FORD MOTOR CO.
Install the intermediate clutch return spring.

Fig 3: Locating Intermediate Clutch Return Spring
Courtesy of FORD MOTOR CO.
Install the intermediate clutch return spring top plate.

Fig 4: Locating Intermediate Clutch Return Spring Top Plate
Courtesy of FORD MOTOR CO.
Using the Clutch Spring Compressor 307-525, install a new intermediate clutch return spring retainer.

Fig 5: Locating Intermediate Clutch Return Spring Retainer
Courtesy of FORD MOTOR CO.

NOTE: Friction and steel plate quantity will vary based on engine displacement. For additional information, refer to the CLUTCH PLATE QUANTITY CHART .

Fig 6: Identifying Intermediate Clutch Plates

Courtesy of FORD MOTOR CO.

Soak the new intermediate clutch plates in clean automatic transmission fluid.
Install the new intermediate clutch plates, starting with the wave spring then a steel plate and alternating between friction and steel plates, and ending with the pressure plate.

Fig 7: Locating Pressure Plate
Courtesy of FORD MOTOR CO.
Install the intermediate clutch plate snap ring.

Fig 8: Locating Intermediate Clutch Plate Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: All intermediate clutch plates, friction and steel are of a wave-type design.

Fig 9: Identifying Clutch End Play Gauge 307-555 And Dial Indicator Gauge With Holding Fixture 100-002

Courtesy of FORD MOTOR CO.

Install the intermediate 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.
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 10: Lifting Up On Steel Pressure Plate
Courtesy of FORD MOTOR CO.

Rotate the intermediate 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

NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.

- 5.4L engine - 0.7-1.1 mm (0.027-0.043 in).
- 4.6L engine - 0.7-1.1 mm (0.027-0.043 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.
Install the T6 thrust bearing.

Fig 11: Locating T6 Thrust Bearing
Courtesy of FORD MOTOR CO.