Overdrive Clutch Assembly: Assembly

Install the 3 new scarf cut seals and the roller bearing.

Fig 1: Locating Scarf Cut Seals And Roller Bearing
Courtesy of FORD MOTOR CO.
Install a new outer O-ring seal on the O/D clutch balance piston.

Fig 2: Locating Outer O-Ring Seal On O/D Clutch Balance Piston
Courtesy of FORD MOTOR CO.
Install 2 new inner O-ring seals on the O/D clutch apply piston.

Fig 3: Locating Inner O-Ring Seals On O/D Clutch Apply Piston
Courtesy of FORD MOTOR CO.
Lubricate all the O-ring seals with clean transmission fluid. Install the O/D clutch apply piston into the drum with the O-ring seals and the 3 pads facing down toward the drum.

Fig 4: Locating O/D Clutch Apply Piston
Courtesy of FORD MOTOR CO.

NOTE: The fingers on the return spring are facing down toward the piston.

Fig 5: Locating O/D Clutch Return Spring

Courtesy of FORD MOTOR CO.

NOTE: The cone shape of the balance piston must face up when installed correctly.

Fig 6: Locating O/D Clutch Balance Piston

Courtesy of FORD MOTOR CO.

Lubricate all the O-ring seals with clean transmission fluid. Install the O/D clutch balance piston.
Using the Spring Washer Compressor 307-209, install a new O/D clutch balance piston retaining ring.

Fig 7: Locating O/D Clutch Balance Piston Retaining Ring
Courtesy of FORD MOTOR CO.
Soak the new O/D clutch plates in clean transmission fluid.

Fig 8: Identifying O/D Clutch Plates
Courtesy of FORD MOTOR CO.
Install the new O/D clutch plates, starting with a steel plate and alternating between friction and steel plates, and ending with the pressure plate on the top.

Fig 9: Locating Pressure Plate On Top
Courtesy of FORD MOTOR CO.
Install the O/D clutch pack snap ring.

Fig 10: Locating O/D Clutch Pack Snap Ring
Courtesy of FORD MOTOR CO.

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

Fig 11: Identifying O/D Clutch Assembly Into Clutch End Play Gauge 307-555 And Dial Indicator Gauge With Holding Fixture 100-002

Courtesy of FORD MOTOR CO.

Install the O/D 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 12: Lifting Up On Steel Pressure Plate
Courtesy of FORD MOTOR CO.

Rotate the O/D clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.

READING DESCRIPTION REFERENCE

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 - 0.5-0.9 mm (0.019-0.035 in).
- 4.6L engine - 0.5-0.9 mm (0.019-0.035 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.

NOTE: Inspect and install new thrust bearings as required.

Fig 13: Locating T3 Thrust Bearing

Courtesy of FORD MOTOR CO.