Direct Clutch Assembly: Assembly

Install a new inner and outer O-ring seal on the apply piston.

Fig 1: Locating Inner And Outer O-Ring Seal On Apply Piston
Courtesy of FORD MOTOR CO.
Install a new outer O-ring seal on the balance piston.

Fig 2: Installing Outer O-Ring Seal On Balance Piston
Courtesy of FORD MOTOR CO.
Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.

Fig 3: Locating Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Install the direct clutch return spring.

Fig 4: Locating Direct Clutch Return Spring
Courtesy of FORD MOTOR CO.
Install the balance piston.

Fig 5: Locating Balance Piston
Courtesy of FORD MOTOR CO.
Install the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015 onto the direct clutch assembly.

Fig 6: Identifying Clutch Spring Compressor 307-552 And Clutch Spring Compressor 307-015
Courtesy of FORD MOTOR CO.
Using the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015, compress the direct clutch return spring and install the direct clutch return spring retainer.

Fig 7: Identifying Clutch Spring Compressor 307-552 And Clutch Spring Compressor 307-015
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 8: Identifying Direct Clutch

Courtesy of FORD MOTOR CO.

Soak the new direct clutch in clean transmission fluid.
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.

Fig 9: Locating Pressure Plate
Courtesy of FORD MOTOR CO.
Install the direct clutch snap ring.

Fig 10: Locating Direct Clutch Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: Inspect and install a new thrust bearing as required.

Fig 11: Locating T5 Thrust Bearing

Courtesy of FORD MOTOR CO.

Install the T5 thrust bearing.

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

Fig 12: Identifying Clutch End Play Gauge 307-555 And Dial Indicator Gauge With Holding Fixture 100-002

Courtesy of FORD MOTOR CO.

Install the direct 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 13: Lifting Up On Steel Pressure Plate
Courtesy of FORD MOTOR CO.

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.

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 - 0.5-1.3 mm (0.019-0.051 in).
- 4.6L engine - 0.5-1.3 mm (0.019-0.051 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 2 new scarf cut seals and the roller bearing.

Fig 14: Locating Scarf Cut Seals And Roller Bearing
Courtesy of FORD MOTOR CO.