LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2011 >> Flex Titanium, 3.5 C, AWD >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Automatic Transaxle/Transmission - 6F50-6F55 - General Procedures, In-Vehicle Repair, Removal, Disassembly And Assembly Of Subassemblies, Assembly, Installation >> Disassembly And Assembly Of Subassemblies >> Overdrive/Direct Clutch Assembly >> Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Overdrive/Direct Clutch Assembly: Assembly

  1. Install the direct clutch wave spring.
    Fig 1: Locating Direct Clutch Wave Spring
    G07467957Courtesy of FORD MOTOR CO.
  2. Lubricate the direct clutch pack in clean transmission fluid.
    Fig 2: Identifying Direct Clutch Pack
    G07467958Courtesy of FORD MOTOR CO.
  3. Install the direct clutch assembly and pressure plate.
    Fig 3: Remove/Install Direct Clutch Pressure Plate, Clutch Assembly And Wave Spring
    G07467959Courtesy of FORD MOTOR CO.
  4. Install the direct clutch snap ring.
    Fig 4: Remove/Install Direct Clutch Snap Ring
    G07467960Courtesy 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
    G07467961Courtesy of FORD MOTOR CO.
  6. Install the direct clutch piston return spring.
    Fig 6: Remove/Install Direct Clutch Piston Return Spring
    G07467962Courtesy of FORD MOTOR CO.
  7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
    Fig 7: Remove/Install Direct Clutch Piston
    G07467963Courtesy of FORD MOTOR CO.
  8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
    Fig 8: Remove/Install Rear Direct Clutch Piston Seal
    G07467964Courtesy of FORD MOTOR CO.
  9. Install the direct clutch cylinder.
    Fig 9: Remove/Install Direct Clutch Cylinder
    G07467965Courtesy 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.
  10. 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: Remove/Install Snap Ring
      G07467966Courtesy 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: Removing Overdrive Clutch, Balance Piston, Direct Clutch Compressor And Forward/Intermediate Spring Compressor
    G07467967Courtesy 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
    G07467968Courtesy 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
    G07467969Courtesy 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: Pushing Overdrive Clutch Piston In Cylinder
    G07467970Courtesy of FORD MOTOR CO.
    15. NOTE: Install the overdrive clutch piston return spring so that the holes are facing upward.
    Fig 15: Locating Overdrive Piston Return Spring
    G07467971Courtesy of FORD MOTOR CO.
  15. Install the overdrive clutch piston return spring.
  16. Lubricate the seals on a new balance piston with petroleum jelly.
    Fig 16: Locating Seals On Balance Piston
    G07467972Courtesy 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: Installing Overdrive Clutch, Balance Piston, Direct Clutch Compressor And Forward/Intermediate Spring Compressor
    G07467973Courtesy of FORD MOTOR CO.
  18. Using a press, compress the overdrive clutch piston return spring and install the snap ring.
    Fig 18: Locating Balance Piston Snap Ring
    G07467974Courtesy 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: Removing Overdrive Clutch, Balance Piston, Direct Clutch Compressor And Forward/Intermediate Spring Compressor
    G07467975Courtesy of FORD MOTOR CO.
  20. Install the No. 2 rear sun gear thrust bearing.
    Fig 20: Remove/Install No. 2 Rear Sun Gear Thrust Bearing
    G07467976Courtesy of FORD MOTOR CO.
  21. Install the overdrive clutch hub.
    Fig 21: Installing Overdrive Clutch Hub
    G07467977Courtesy of FORD MOTOR CO.
  22. Lubricate the overdrive clutch pack in clean transmission fluid.
    Fig 22: Identifying Overdrive Clutch Pack
    G07467978Courtesy of FORD MOTOR CO.
  23. Install the overdrive clutch pack assembly and the pressure plate.
    Fig 23: Locating Overdrive Clutch Pack Assembly
    G07467979Courtesy of FORD MOTOR CO.
  24. Install the overdrive clutch pack snap ring.
    Fig 24: Locating Overdrive Clutch Pack Snap Ring
    G07467980Courtesy 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: Positioning Dial Indicator Gauge With Holding Fixture 100-002 On Overdrive/Direct Clutch Assembly
    G07467981Courtesy 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: Positioning Dial Indicator Gauge With Holding Fixture 100-002 On Direct Clutch Pressure Plate
    G07467982Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals