Forward Clutch Assembly: Disassembly

NOTE: Clutch plate quantity is model dependent based on engine displacement:

4.6L engine (Explorer, Mountaineer, Sport Trac, F-150)
- Four friction plates
- Five steel plates
5.4L engine (Expedition, Navigator, F-150)
- Five friction plates
- Six steel plates

If the T2 thrust bearing is on the forward clutch assembly, remove it from the forward clutch assembly.

Fig 1: Removing T2 Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the front planetary carrier and sun gear from the forward clutch assembly.
- With a small screwdriver or a suitable pick inserted into the front planetary assembly, push on the retaining ring in 4 places while lifting up on the front planetary assembly.
  
  Fig 2: Removing Front Planetary Carrier And Sun Gear From Forward Clutch Assembly
  Courtesy of FORD MOTOR CO.
Remove the forward clutch pack snap ring.

Fig 3: Locating Forward Clutch Pack Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: Inspect the forward clutch drum and the friction and steel plates for damage. Install new components as necessary.

Remove and inspect the forward clutch steel and friction plates.
- If the plates are damaged, install a new forward clutch assembly.
- If no damage is indicated, the forward clutch may be reassembled.
  
  Fig 4: Locating Forward Clutch Steel And Friction Plates
  Courtesy of FORD MOTOR CO.
For correct alignment during assembly, make an identifying mark on the balance dam and the center part of the housing.

Fig 5: Locating Identifying Mark On Balance Dam And Center Part Of Housing
Courtesy of FORD MOTOR CO.

NOTE: The bottom of the Clutch Spring Compressor 307-525 will need to be installed from the back side of the forward clutch assembly.

Fig 6: Identifying Clutch Spring Compressor 307-525

Courtesy of FORD MOTOR CO.

Using the Clutch Spring Compressor 307-525, slightly collapse the balance dam to gain access to the retaining ring and remove the retaining ring.
Remove the balance dam.

Fig 7: Locating Balance Dam
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seal from the balance dam.

Fig 8: Removing O-Ring Seal From Balance Dam
Courtesy of FORD MOTOR CO.
Remove the forward clutch return spring.

Fig 9: Locating Forward Clutch Return Spring
Courtesy of FORD MOTOR CO.
Install the forward clutch on the front pump to remove the forward clutch piston. Apply a small amount of shop air to remove the piston.

Fig 10: Removing Forward Clutch Piston
Courtesy of FORD MOTOR CO.
Remove and discard the inner and outer piston O-ring seals.

Fig 11: Removing Inner And Outer Piston O-Ring Seals
Courtesy of FORD MOTOR CO.
Remove the sun gear from the planet assembly.

Fig 12: Locating Sun Gear In Planet Assembly
Courtesy of FORD MOTOR CO.

NOTE: The T1 thrust bearing may have stuck to the sun gear when it was removed.

Fig 13: Removing T1 Bearing From Planetary Carrier

Courtesy of FORD MOTOR CO.

Remove the T1 bearing from the planetary carrier.
Remove the transmission fluid collector plate from the front planetary carrier.

Fig 14: Removing Transmission Fluid Collector Plate From Front Planetary Carrier
Courtesy of FORD MOTOR CO.
Clean and inspect the components of the forward clutch assembly for damage and install new components as necessary.