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Home >> Ford >> 2011 >> Fusion S, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle - 6F35 - Disassembly, Disassembly And Assembly Of Subassemblies, Assembly, Installation >> Disassembly And Assembly Of Subassemblies >> Overdrive/Direct Clutch Assembly >> Assembly
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Overdrive/Direct Clutch Assembly: Assembly

  1. Clean and inspect the O/D/direct clutch assembly for damage or excessive wear and install new components as necessary.
  2. Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.
    Fig 1: Locating Direct (3, 5, R) Clutch Piston Seals
    G07783333Courtesy of FORD MOTOR CO.
  3. Install the direct (3, 5, R) clutch wave spring.
    Fig 2: Locating Direct (3, 5, R) Clutch Wave Spring
    G07783334Courtesy of FORD MOTOR CO.
  4. Soak the direct (3, 5, R) clutch pack in clean automatic transmission fluid.
    Fig 3: Identifying Direct (3, 5, R) Clutch Pack
    G07783335Courtesy of FORD MOTOR CO.
  5. Install the direct (3, 5, R) clutch assembly and pressure plate.
    Fig 4: Locating Direct (3, 5, R) Clutch Assembly And Pressure Plate
    G07783336Courtesy of FORD MOTOR CO.
  6. Install the direct (3, 5, R) clutch snap ring.
    1. Using a suitable tool, compress the snap ring.
    2. Lift the direct (3, 5, R) clutch so that the snap ring is in the groove of the pressure plate.
    3. Release the tension on the snap ring.
      Fig 5: Releasing Tension On Snap Ring
      G07783337Courtesy of FORD MOTOR CO.
    7. NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
    Fig 6: Locating Direct (3, 5, R) Clutch Piston Return Spring
    G07783338Courtesy of FORD MOTOR CO.
  7. Install the direct (3, 5, R) clutch piston return spring.
  8. Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.
    Fig 7: Locating Direct (3, 5, R) Clutch Piston
    G07783339Courtesy of FORD MOTOR CO.
  9. Install the direct (3, 5, R) clutch cylinder.
    Fig 8: Locating Direct (3, 5, R) Clutch Cylinder
    G07783340Courtesy of FORD MOTOR CO.
    10. NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
  10. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
    1. Do not contact the O/D/direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
    2. Install the snap ring.
      Fig 9: Remove/Install Snap Ring
      G07783341Courtesy of FORD MOTOR CO.
  11. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 10: Identifying Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G07783342Courtesy of FORD MOTOR CO.
  12. Install 2 new seals on the O/D (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
    Fig 11: Locating Seals On O/D (4, 5, 6) Clutch Piston
    G07783343Courtesy of FORD MOTOR CO.
  13. Install a new O/D (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.
    Fig 12: Locating O/D (4, 5, 6) Clutch Piston Inner Seal
    G07783344Courtesy of FORD MOTOR CO.
  14. Position the O/D (4, 5, 6) clutch piston in place.
    Fig 13: Locating O/D (4, 5, 6) Clutch Piston
    G07783345Courtesy of FORD MOTOR CO.
  15. Using the Overdrive Clutch, Balance Piston, and Direct Clutch Compressor 307-589/1, install the O/D (4, 5, 6) clutch piston into the O/D/direct clutch assembly by hand.
    Fig 14: Installing O/D (4, 5, 6) Clutch Piston Into O/D/Direct Clutch Assembly
    G07783346Courtesy of FORD MOTOR CO.
    16. NOTE: Holes face up on the O/D (4, 5, 6) clutch piston return spring.
    Fig 15: Locating O/D (4, 5, 6) Clutch Piston Return Spring
    G07783347Courtesy of FORD MOTOR CO.
  16. Install the O/D (4, 5, 6) clutch piston return spring.
  17. Lubricate the seals on a new balance piston and position the piston in place.
    Fig 16: Locating Seals On Balance Piston
    G07783348Courtesy of FORD MOTOR CO.
  18. 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
    G07783349Courtesy of FORD MOTOR CO.
  19. Using a press, compress the O/D (4, 5, 6) clutch return spring and install the snap ring.
    Fig 18: Compressing O/D (4, 5, 6) Clutch Return Spring
    G07783350Courtesy of FORD MOTOR CO.
  20. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 19: Identifying Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G07783351Courtesy of FORD MOTOR CO.
  21. Install the No. 2 thrust bearing.
    Fig 20: Locating No. 2 Thrust Bearing
    G07783352Courtesy of FORD MOTOR CO.
  22. Install the O/D (4, 5, 6) clutch hub.
    Fig 21: Locating O/D (4, 5, 6) Clutch Hub
    G07783353Courtesy of FORD MOTOR CO.
  23. Soak the O/D (4, 5, 6) clutch pack in clean automatic transmission fluid.
    Fig 22: Identifying O/D (4, 5, 6) Clutch Pack
    G07783354Courtesy of FORD MOTOR CO.
  24. Install the O/D (4, 5, 6) clutch pack.
    Fig 23: Locating O/D (4, 5, 6) Clutch Pack
    G07783355Courtesy of FORD MOTOR CO.
  25. Install the O/D (4, 5, 6) clutch pressure plate.
    Fig 24: Locating O/D (4, 5, 6) Clutch Pressure Plate
    G07783356Courtesy of FORD MOTOR CO.
  26. Install the O/D (4, 5, 6) clutch snap ring.
    Fig 25: Locating O/D (4, 5, 6) Clutch Snap Ring
    G07783357Courtesy of FORD MOTOR CO.
  27. Install the input shaft.
    Fig 26: Identifying Input Shaft
    G07783358Courtesy of FORD MOTOR CO.
  28. While holding the input shaft in place, install the snap ring.
    Fig 27: Locating Input Shaft Snap Ring
    G07783359Courtesy of FORD MOTOR CO.
  29. Position the O/D/direct clutch assembly in the transaxle case, install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the O/D (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the O/D (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the O/D (4, 5, 6) clutch pack for correct installation. If the O/D (4, 5, 6) clutch pack is correctly installed, install a new O/D (4, 5, 6) clutch pack.
    Fig 28: Applying Air Pressure To O/D (4, 5, 6) Clutch Piston Port
    G07783360Courtesy of FORD MOTOR CO.
  30. Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator Gauge With Holding Fixture 100-002. The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.
    Fig 29: Applying Air Pressure To Direct (3, 5, R) Clutch Piston Port
    G07783361Courtesy of FORD MOTOR CO.
  31. Remove Dial Indicator Gauge With Holding Fixture 100-002, O/D/direct clutch assembly and the No. 1 O/D/direct clutch assembly thrust bearing.
    Fig 30: Identifying Dial Indicator Gauge With Holding Fixture 100-002
    G07783362Courtesy of FORD MOTOR CO.
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