Direct Clutch Assembly: Disassembly

NOTE: Clutch plate quantity is model dependent based on engine displacement:

4.6L engine (Explorer, Mountaineer, Sport Trac, F-150)
- Four friction plates
- Five steel plates
5.4L engine (Expedition, Navigator, F-150)
- Five friction plates
- Six steel plates

Remove and discard the 2 scarf cut seals and the roller bearing.

Fig 1: Removing Scarf Cut Seals And Roller Bearing
Courtesy of FORD MOTOR CO.
Remove the T5 thrust bearing.

Fig 2: Locating T5 Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the direct clutch snap ring.

Fig 3: Locating Direct Clutch Snap Ring
Courtesy of FORD MOTOR CO.
Remove the direct clutch steel and friction plates.

Fig 4: Locating Direct Clutch Steel And Friction Plates
Courtesy of FORD MOTOR CO.
Install the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015 onto the direct clutch assembly.

Fig 5: Identifying Clutch Spring Compressor 307-552 And Clutch Spring Compressor 307-015
Courtesy of FORD MOTOR CO.
Using the Clutch Spring Compressor 307-552 and Clutch Spring Compressor 307-015, compress the direct clutch return spring and remove the direct clutch return spring retainer.

Fig 6: Identifying Clutch Spring Compressor 307-552 And Clutch Spring Compressor 307-015
Courtesy of FORD MOTOR CO.
Remove the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015.

Fig 7: Identifying Clutch Spring Compressor 307-552 And Clutch Spring Compressor 307-015
Courtesy of FORD MOTOR CO.
Remove the balance piston.

Fig 8: Locating Balance Piston
Courtesy of FORD MOTOR CO.
Remove the direct clutch return spring.

Fig 9: Locating Direct Clutch Return Spring
Courtesy of FORD MOTOR CO.
Remove the direct clutch piston.

Fig 10: Locating Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Remove and discard the outer O-ring seal from the balance piston.

Fig 11: Removing Outer O-Ring Seal From Balance Piston
Courtesy of FORD MOTOR CO.
Remove and discard the outer and inner O-ring seals from the apply piston.

Fig 12: Removing Outer And Inner O-Ring Seals From Apply Piston
Courtesy of FORD MOTOR CO.
Inspect the components of the direct clutch for damage. If damage is indicated, install new components as necessary.