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Overdrive/Direct Clutch Assembly: Disassembly

  1. Remove the input shaft snap ring.
    Fig 1: Locating Input Shaft Snap Ring
    G08023719Courtesy of FORD MOTOR CO.
  2. Remove the input shaft.
    Fig 2: Locating Input Shaft
    G08023720Courtesy 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
    G08023721Courtesy 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
    G08023722Courtesy 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
    G08023723Courtesy 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
    G08023724Courtesy 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: Installing Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2 On Balance Piston
    G08023725Courtesy 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
    G08023726Courtesy 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: Removing Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/1 And Forward/Intermediate Spring Compressor 307-584/2
    G08023727Courtesy of FORD MOTOR CO.
  10. Remove and discard the balance piston.
    Fig 10: Locating Balance Piston
    G08023728Courtesy 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
    G08023729Courtesy 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
      G08023730Courtesy 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
    G08023731Courtesy 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
    G08023732Courtesy of FORD MOTOR CO.
  15. Position the O/D/direct clutch assembly in the transaxle case.
    Fig 15: Locating O/D/Direct Clutch Assembly
    G08023733Courtesy 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
    G08023734Courtesy of FORD MOTOR CO.
  17. Remove the O/D/direct clutch assembly from the transaxle case.
    Fig 17: Locating O/D/Direct Clutch Assembly
    G08023735Courtesy 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
    G08023736Courtesy 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
    G08023737Courtesy 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: Removing Snap Ring
      G08023738Courtesy 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: Removing Overdrive Clutch, Balance Piston And Direct Clutch Compressor 307-589/2 And Forward/Intermediate Spring Compressor 307-584/2
    G08023739Courtesy of FORD MOTOR CO.
  22. Remove the direct (3, 5, R) clutch cylinder.
    Fig 22: Removing Direct (3, 5, R) Clutch Cylinder
    G08023740Courtesy of FORD MOTOR CO.
  23. Remove and discard the direct (3, 5, R) clutch piston.
    Fig 23: Removing Direct (3, 5, R) Clutch Piston
    G08023741Courtesy 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
    G08023742Courtesy 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 Direct (3, 5, R) Clutch Snap Ring
      G08023743Courtesy 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
    G08023744Courtesy 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 Seals
    G08023745Courtesy of FORD MOTOR CO.
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