Intermediate 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
- Four steel plates
5.4L engine (Expedition, Navigator, F-150)
- Five friction plates
- Five steel plates

Remove the T6 thrust bearing.

Fig 1: Locating T6 Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the intermediate clutch plate snap ring.

Fig 2: Locating Intermediate Clutch Plate Snap Ring
Courtesy of FORD MOTOR CO.
Remove the intermediate clutch plates.

Fig 3: Locating Intermediate Clutch Plates
Courtesy of FORD MOTOR CO.
Using the Clutch Spring Compressor 307-525, remove and discard the intermediate clutch return spring retainer.

Fig 4: Locating Intermediate Clutch Return Spring Retainer
Courtesy of FORD MOTOR CO.
Remove the intermediate clutch return spring top plate.

Fig 5: Locating Intermediate Clutch Return Spring Top Plate
Courtesy of FORD MOTOR CO.
Remove the intermediate clutch return spring.

Fig 6: Locating Intermediate Clutch Return Spring
Courtesy of FORD MOTOR CO.
Applying a slight amount of air to the port, remove the intermediate clutch piston.

Fig 7: Locating Intermediate Clutch Piston
Courtesy of FORD MOTOR CO.
Remove and discard the inner and outer intermediate clutch piston O-ring seals.

Fig 8: Removing Inner And Outer Intermediate Clutch Piston O-Ring Seals
Courtesy of FORD MOTOR CO.