Direct Clutch Drum Assembly: Material

• Inspect the drum surface for damage.
• Inspect the clutch piston bore, and piston.
• Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
• Inspect the clutch plates for damage.
• Inspect the clutch springs.

1. Disassemble the components in the order indicated in the following illustration.
2. To assemble, reverse the disassembly procedure.
   Fig 2: Disassembling Sequence Of Direct Clutch Drum Assembly

   Courtesy of FORD MOTOR CO.

Item 5: Retaining Ring Disassembly Note 

WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.
CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.
Fig 3: Removing Direct Clutch Piston Retaining Ring
Courtesy of FORD MOTOR CO.
1. Using the special tool, remove the direct clutch piston retaining ring.

Item 8: Direct and Overdrive Clutch Piston Disassembly Note 

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.
1. Using compressed air, remove the direct clutch piston from the direct clutch drum.
   • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
     Fig 4: Locating Hole

     Courtesy of FORD MOTOR CO.

Item 11: Intermediate Brake Drum Assembly Note 

1. Verify the check ball is free to move.
   Fig 5: Verifying Check Ball

   Courtesy of FORD MOTOR CO.

Items 9 and 10: Direct and Overdrive Piston Outer and Inner Seal Ring Inspection Note 

1. Inspect the clutch components for damage or wear. Install new components as necessary.
   • Inspect the drum surface for damage.
   • Inspect the clutch piston bore, and piston.
   • Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
   • Inspect the clutch plates for damage.
   • Inspect the clutch springs.

Items 9 and 10: Direct and Overdrive Piston Outer and Inner Seal Ring Assembly Note 

CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
NOTE: Use new seals to help prevent seal failures.
Fig 6: Installing Direct Clutch Piston Inner And Outer Seal
Courtesy of FORD MOTOR CO.
1. Install the new direct clutch piston inner seal and the direct clutch piston outer seal.
CAUTION: Care must be taken to prevent damage to the seals during installation.
Fig 7: Installing Direct Clutch Piston
Courtesy of FORD MOTOR CO.
2. Lubricate the seals with transmission fluid before installing. Using the special tool, install the direct clutch piston.

Item 5: Retaining Ring Assembly Note 

WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.
CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.
Fig 8: Installing Direct Clutch Piston Retaining Ring
Courtesy of FORD MOTOR CO.
1. Using the special tool, install the direct clutch piston retaining ring.

Items 4 and 3: Direct Clutch External Spline Steel and Internal Spline Friction Plates Assembly Note 

CAUTION: The direct clutch friction plates are directional and must be installed correctly. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates.
CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid for at least 30 minutes before assembly.
Fig 9: Identifying Splines On Friction Plates
Courtesy of FORD MOTOR CO.
1. When installing friction plates, alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates. Install the direct clutch disc pack.
2. Install the friction plates. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates starting with an externally splined (counterclockwise) clutch plate.
   Fig 10: Installing Friction Plates

   Courtesy of FORD MOTOR CO.

Item 1: Retaining Ring Assembly Note 

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.
1. Air check the assembly.
   • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
     Fig 11: Locating Drum Hole

     Courtesy of FORD MOTOR CO.
2. Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.
   • If specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.