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Overdrive/Direct Clutch Assembly: Assembly

  1. Install the direct clutch wave spring.
    Fig 1: Locating Direct Clutch Wave Spring
    G06076375Courtesy of FORD MOTOR CO.
  2. Lubricate the direct clutch pack in clean transmission fluid.
    Fig 2: Identifying Direct Clutch Pack
    G06068532Courtesy of FORD MOTOR CO.
  3. Install the direct clutch assembly and pressure plate.
    Fig 3: Installing Direct Clutch Assembly And Pressure Plate
    G06068530Courtesy of FORD MOTOR CO.
  4. Install the direct clutch snap ring.
    Fig 4: Installing Direct Clutch Snap Ring
    G06068529Courtesy of FORD MOTOR CO.
  5. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
    Fig 5: Installing Direct Clutch Piston Seals
    G06068535Courtesy of FORD MOTOR CO.
  6. Install the direct clutch piston return spring.
    Fig 6: Installing Direct Clutch Piston Return Spring
    G06076371Courtesy of FORD MOTOR CO.
  7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
    Fig 7: Installing Direct Clutch Piston
    G06076370Courtesy of FORD MOTOR CO.
  8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
    Fig 8: Installing Rear Direct Clutch Piston Seal
    G06068525Courtesy of FORD MOTOR CO.
  9. Install the direct clutch cylinder.
    Fig 9: Installing Direct Clutch Cylinder
    G06068539Courtesy of FORD MOTOR CO.
  10. NOTE: Only compress the direct clutch piston return spring far enough to install the direct clutch cylinder snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
    NOTE: Align the tab on the direct clutch cylinder with the slot on the overdrive/direct clutch hub and shaft assembly.

    Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring and install the snap ring.

    1. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder.
    2. Install the snap ring.
    Fig 10: Identifying Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G06068522Courtesy of FORD MOTOR CO.
  11. Remove the Overdrive Clutch, Balance Piston Direct Clutch Compressor 307-589/2 and the Forward/Intermediate Spring Compressor 307-584/2.
    Fig 11: Identifying Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G06068523Courtesy of FORD MOTOR CO.
  12. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
    Fig 12: Installing Seals On Overdrive Clutch Piston
    G06068542Courtesy of FORD MOTOR CO.
  13. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
    Fig 13: Locating Overdrive Clutch Piston Inner Seal
    G06076387Courtesy of FORD MOTOR CO.
  14. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1.
    Fig 14: Identifying Direct Clutch Compressor 307-589/1
    G06068544Courtesy of FORD MOTOR CO.
  15. NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.

    Install the overdrive clutch piston return spring.

    Fig 15: Locating Overdrive Clutch Piston Return Spring
    G06068545Courtesy of FORD MOTOR CO.
  16. Lubricate the seals on a new balance piston with petroleum jelly.
    Fig 16: Locating Seals On Balance Piston
    G06068546Courtesy of FORD MOTOR CO.
  17. Install the new balance piston and install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
    Fig 17: Identifying Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G06068513Courtesy of FORD MOTOR CO.
  18. Using a press, compress the overdrive clutch piston return spring and install the snap ring.
    Fig 18: Locating Snap Ring
    G06076357Courtesy of FORD MOTOR CO.
  19. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and the Forward/Intermediate Spring Compressor 307-584/2 from the balance piston.
    Fig 19: Identifying Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G06260552Courtesy of FORD MOTOR CO.
  20. Install the No. 2 rear sun gear thrust bearing.
    Fig 20: Installing No. 2 Rear Sun Gear Thrust Bearing
    G06068510Courtesy of FORD MOTOR CO.
  21. Install the overdrive clutch hub.
    Fig 21: Installing Overdrive Clutch Hub
    G06068551Courtesy of FORD MOTOR CO.
  22. Lubricate the overdrive clutch pack in clean transmission fluid.
    Fig 22: Identifying Overdrive Clutch Pack
    G06068552Courtesy of FORD MOTOR CO.
  23. Install the overdrive clutch pack assembly and the pressure plate.
    Fig 23: Locating Overdrive Clutch Pack Assembly
    G06076397Courtesy of FORD MOTOR CO.
  24. Install the overdrive clutch pack snap ring.
    Fig 24: Locating Overdrive Clutch Pack Snap Ring
    G06068554Courtesy of FORD MOTOR CO.
  25. Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator Gauge with Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.089 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
    Fig 25: Applying 483 KPA (70 psi) Of Air Pressure To Overdrive Clutch Piston Port
    G06068555Courtesy of FORD MOTOR CO.
  26. Position the Dial Indicator Gauge with Holding Fixture 100-002 on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 0.98 mm (0.038 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.
Fig 26: Applying 483 KPA (70 psi) Of Air Pressure To Direct Clutch Piston Port
G06068556Courtesy of FORD MOTOR CO.
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