Direct Clutch Cylinder: Assembly

NOTE: The lip on the seal must face toward the bottom of the clutch cylinder.

Fig 1: Installing Inner Piston Seal

Courtesy of FORD MOTOR CO.

NOTE: Make sure that the check ball is in place on the clutch piston. Lightly coat all the seals with petroleum jelly prior to installation.

Fig 2: Installing Direct Clutch Piston

Courtesy of FORD MOTOR CO.

Using the special tool, install the direct clutch piston and seal assembly making sure that it is fully seated.
Install the apply ring. Make sure that it is fully seated on the clutch piston.

Fig 3: Installing Apply Ring
Courtesy of FORD MOTOR CO.

NOTE: The notch on the direct clutch return spring must line up with the check ball on the direct clutch piston.

Fig 4: Installing Direct Clutch Return Spring

Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the special tool to bottom out on the piston.

Fig 5: Compressing Clutch Spring

Courtesy of FORD MOTOR CO.

Using the special tool and snap ring pliers, compress the clutch spring and install the snap ring.

CAUTION: Check for wear on the inner splines of the friction plates. Install new if worn.

NOTE: The number of clutch plates may vary with application.

NOTE: The clutch pressure plate must be installed with the chamfer edge facing up.

Install the intermediate clutch pack.
1. Install the intermediate clutch pack.
2. Install the clutch pressure plate.
3. Install the snap ring.
  
  Fig 6: Installing Clutch Pressure Plate
  Courtesy of FORD MOTOR CO.
Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.

Fig 7: Measuring Clearance Between Retaining Ring
Courtesy of FORD MOTOR CO.
If the clearance is not within specification, selective retaining rings are available. Check the clearance after installing the correct selective retaining ring.

Fig 8: Selective Retaining Ring Chart

Courtesy of FORD MOTOR CO.