Direct Clutch Assembly: Assembly

Install a new inner and outer O-ring seal on the apply piston.

Fig 1: Locating Inner And Outer O-Ring Seal On Apply Piston
Courtesy of FORD MOTOR CO.
Install a new outer O-ring seal on the balance piston.

Fig 2: Installing Outer O-Ring Seal On Balance Piston
Courtesy of FORD MOTOR CO.
Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.

Fig 3: Locating Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Install the direct clutch return spring.

Fig 4: Locating Direct Clutch Return Spring
Courtesy of FORD MOTOR CO.
Install the balance piston.

Fig 5: View Of Balance Piston
Courtesy of FORD MOTOR CO.
Install the Clutch Spring Compressors onto the direct clutch assembly.

Fig 6: Installing Clutch Spring Compressors Onto Direct Clutch Assembly
Courtesy of FORD MOTOR CO.
Using the Clutch Spring Compressors, compress the direct clutch return spring and install the direct clutch return spring retainer.

Fig 7: Compressing Direct Clutch Return Spring Using Special Tools
Courtesy of FORD MOTOR CO.

NOTE: Friction and steel plate quantity will vary based on engine displacement. For additional information, refer to the CLUTCH PLATE QUANTITY CHART in the Specifications portion of this service information.

Fig 8: Identifying Direct Clutch Plates

Courtesy of FORD MOTOR CO.

Soak the new direct clutch in clean transmission fluid.
Install the new direct clutch plates, starting with the wave spring then a steel plate and alternating between steel and friction plates, and ending with the pressure plate on the top.

Fig 9: View Of Direct Clutch Steel And Friction Plates
Courtesy of FORD MOTOR CO.
Install the direct clutch snap ring.

Fig 10: View Of Direct Clutch Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: Inspect and install a new thrust bearing as required.

Fig 11: Locating T5 Thrust Bearing

Courtesy of FORD MOTOR CO.

Install the T5 thrust bearing.

NOTE: All direct clutch plates, friction and steel are of a wave-type design.

Fig 12: Installing Direct Clutch Assembly Into Clutch End Play Gauge Using Special Tools

Courtesy of FORD MOTOR CO.

Install the direct clutch assembly into the Clutch End Play Gauge and install the Dial Indicator Gauge with Holding Fixture and position the plunger so it fits into the opening of the snap ring.
With the Dial Indicator Gauge set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.

Fig 13: Lifting Up Steel Pressure Plate Using Special Tools
Courtesy of FORD MOTOR CO.

Rotate the direct clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.

READING DESCRIPTION CHART

Description	Reading
Reading A
Reading B
Add reading A to reading B for a total end clearance
Divide the total reading by 2 for an average end clearance

NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.

- 0.5-1.3 mm (0.019-0.051 in).
If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
Install 2 new scarf cut seals and the roller bearing.

Fig 14: Locating Scarf Cut Seals And Roller Bearing
Courtesy of FORD MOTOR CO.