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Forward Clutch Cylinder: Assembly

  1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if badly scored or damaged.
  2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install new if necessary. Inspect check balls for freedom of movement and correct seating.
  3. Check the clutch release spring for distortion and cracks. Install a new spring (including the wave spring) if distorted or cracked.
  4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if deeply scored or burred.
  5. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
  6. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear.
    7. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench.
    Fig 1: Installing Inner And Outer Forward Clutch Piston Seals
    G03241789Courtesy of FORD MOTOR CO.
  7. Install the inner and outer forward clutch piston seals. Note the direction of the sealing rings before installation.
    8. NOTE: Coat the piston seals and clutch drum sealing area with petroleum jelly.
    Fig 2: Positioning Special Tools On Clutch Piston
    G03241790Courtesy of FORD MOTOR CO.
  8. Position the special tools on the clutch piston.
  9. Using the special tools, install the forward clutch piston into the clutch drum.
    • Push the piston to the bottom of the drum using even pressure.
      Fig 3: Installing Forward Clutch Piston Into Clutch Drum
      G03241791Courtesy of FORD MOTOR CO.
  10. Using the special tool, compress the piston return spring and install the retaining ring.
    Fig 4: Compressing Piston Return Spring And Install Retaining Ring
    G03241792Courtesy of FORD MOTOR CO.
  11. Slowly release the press pressure and remove the forward clutch.
    12. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid.
  12. Install the clutch pack assembly.
    1. Install the pressure ring.
    2. Install the clutch pack.
    3. Install the pressure plate.
      Fig 5: Installing Clutch Pack Assembly
      G03241793Courtesy of FORD MOTOR CO.
  13. Install the clutch pack retaining ring.
    Fig 6: Installing Clutch Pack Retaining Ring
    G03241794Courtesy of FORD MOTOR CO.
  14. Install the special tool on the forward clutch pack.
    • Push downward on the clutch pack.
    • Release pressure and zero the dial indicator.
      Fig 7: Installing Special Tool On Forward Clutch Pack
      G03241795Courtesy of FORD MOTOR CO.
  15. For vehicles equipped with a 3.8L engine, check the clutch pack clearance.
    1. Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer.
    2. Read the dial indicator.
      • If the clearance is not within specifications, install the correct size retaining ring.
        SELECTIVE RETAINING RING MATERIAL SPECIFICATION

        Specification
        1.52-1.62 mm (0.060-0.064 inch)
        1.87-1.98 mm (0.074-0.078 inch)
        2.23-2.69 mm (0.086-0.106 inch)
        2.59-2.69 mm (0.102-0.106 inch)
        Fig 8: Checking Clutch Pack Clearance
        G03241796Courtesy of FORD MOTOR CO.
  16. For vehicles equipped with a 4.6L engine, check the clutch pack clearance.
  1. Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer.
  2. Read the dial indicator.
    • If the clearance is not within specifications, install the correct size retaining ring.
      SELECTIVE RETAINING RING SPECIFICATION CHART

      Specification
      1.52-1.62 mm (0.060-0.064 inch)
      1.87-1.98 mm (0.074-0.078 inch)
      2.23-2.69 mm (0.086-0.106 inch)
      2.59-2.69 mm (0.102-0.106 inch)
      Fig 9: Checking Clutch Pack Clearance
      G03241797Courtesy of FORD MOTOR CO.
    3. NOTE: Make sure the scarf-cut seals are mated correctly.
    Fig 10: Identifying Scarf-Cut Seals
    G03241798Courtesy of FORD MOTOR CO.
  3. Slide the two scarf-cut seals on the input shaft.
  4. Install the two scarf-cut seals on input shaft.
    Fig 11: Installing Two Scarf-Cut Seals On Input Shaft
    G03241799Courtesy of FORD MOTOR CO.
  5. Install the No. 3 forward clutch hub front bearing and the forward clutch hub.
    Fig 12: Installing No. 3 Forward Clutch Hub Front Bearing And Forward Clutch Hub
    G03241800Courtesy of FORD MOTOR CO.
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