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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 >> Disassembly
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Overdrive/Direct Clutch Assembly: Disassembly

  1. Remove the input shaft snap ring.
    Fig 1: Locating Input Shaft Snap Ring
    G07783306Courtesy of FORD MOTOR CO.
  2. Remove the input shaft.
    Fig 2: Identifying Input Shaft
    G07783307Courtesy of FORD MOTOR CO.
  3. Remove the Overdrive (O/D) (4, 5, 6) clutch hub.
    Fig 3: Locating Overdrive (O/D) (4, 5, 6) Clutch Hub
    G07783308Courtesy of FORD MOTOR CO.
  4. Remove the O/D (4, 5, 6) clutch hub, No. 2 thrust bearing.
    Fig 4: Locating O/D (4, 5, 6) Clutch Hub, No. 2 Thrust Bearing
    G07783309Courtesy of FORD MOTOR CO.
  5. Remove the O/D (4, 5, 6) clutch snap ring.
    Fig 5: Locating O/D (4, 5, 6) Clutch Snap Ring
    G07783310Courtesy of FORD MOTOR CO.
  6. Remove the O/D (4, 5, 6) clutch pressure plate and clutch assembly.
    Fig 6: Locating O/D (4, 5, 6) Clutch Pressure Plate And Clutch Assembly
    G07783311Courtesy of FORD MOTOR CO.
  7. 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 7: Identifying Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G07783312Courtesy of FORD MOTOR CO.
  8. Using a press, compress the O/D (4, 5, 6) clutch return spring and remove the snap ring.
    Fig 8: Compressing O/D (4, 5, 6) Clutch Return Spring
    G07783313Courtesy of FORD MOTOR CO.
  9. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 9: Identifying Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G07783314Courtesy of FORD MOTOR CO.
  10. Remove and discard the balance piston.
    Fig 10: Locating Balance Piston
    G07783315Courtesy of FORD MOTOR CO.
  11. Remove the O/D (4, 5, 6) piston return spring.
    Fig 11: Locating O/D (4, 5, 6) Clutch Piston Return Spring
    G07783316Courtesy of FORD MOTOR CO.
  12. Install the clutch support tower in the transmission case and install the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 12: Locating Clutch Support Tower
      G07783317Courtesy of FORD MOTOR CO.
  13. Remove the Input Shaft Support Seal Installer 307-578/1 (sizer).
    Fig 13: Identifying Input Shaft Support Seal Installer 307-578/1
    G07783318Courtesy of FORD MOTOR CO.
  14. Install the No. 1 O/D/direct clutch assembly thrust bearing.
    Fig 14: Locating No. 1 O/D/Direct Clutch Assembly Thrust Bearing
    G07783319Courtesy of FORD MOTOR CO.
  15. Position the O/D/direct clutch assembly in the transaxle case.
    Fig 15: Locating O/D/Direct Clutch Assembly
    G07783320Courtesy of FORD MOTOR CO.
  16. Apply compressed air to the O/D (4, 5, 6) clutch piston port and remove the O/D (4, 5, 6) clutch piston.
    Fig 16: Applying Compressed Air To O/D (4, 5, 6) Clutch Piston Port
    G07783321Courtesy of FORD MOTOR CO.
  17. Remove the O/D/direct clutch assembly from the transaxle case.
    Fig 17: Locating O/D/Direct Clutch Assembly
    G07783322Courtesy of FORD MOTOR CO.
  18. Remove the O/D (4, 5, 6) clutch piston seal from the O/D/direct clutch assembly.
    Fig 18: Removing O/D (4, 5, 6) Clutch Piston Seal
    G07783323Courtesy of FORD MOTOR CO.
  19. Remove the 2 seals from the O/D (4, 5, 6) clutch piston.
    Fig 19: Removing Seals From O/D (4, 5, 6) Clutch Piston
    G07783324Courtesy of FORD MOTOR CO.
    20. 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.
  20. 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 remove 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. Remove the snap ring.
      Fig 20: Remove/Install Snap Ring
      G07783325Courtesy of FORD MOTOR CO.
  21. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 21: Identifying Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G07783326Courtesy of FORD MOTOR CO.
  22. Remove the direct (3, 5, R) clutch cylinder.
    Fig 22: Removing Direct (3, 5, R) Clutch Cylinder
    G07783327Courtesy of FORD MOTOR CO.
  23. Remove and discard the direct (3, 5, R) clutch piston.
    Fig 23: Removing Direct (3, 5, R) Clutch Piston
    G07783328Courtesy of FORD MOTOR CO.
    24. NOTE: Note the position of the return spring for assembly. The flat side faces down.
    Fig 24: Locating Direct (3, 5, R) Clutch Piston Return Spring
    G07783329Courtesy of FORD MOTOR CO.
  24. Remove the direct (3, 5, R) clutch piston return spring.
  25. Remove the direct (3, 5, R) clutch snap ring.
    1. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.
    2. Using a suitable tool, compress the snap ring.
    3. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.
    4. Remove the snap ring.
      Fig 25: Removing Snap Ring
      G07783330Courtesy of FORD MOTOR CO.
  26. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.
    Fig 26: Locating Direct (3, 5, R) Clutch Assembly And Pressure Plate
    G07783331Courtesy of FORD MOTOR CO.
  27. Remove and discard the 3 direct (3, 5, R) clutch piston seals.
    Fig 27: Removing Direct (3, 5, R) Clutch Piston Seal
    G07783332Courtesy of FORD MOTOR CO.
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