Intermediate Clutch Assembly: Assembly
- Install new inner and outer intermediate clutch piston O-ring seals.
- Lightly coat the O-ring seals in clean automatic transmission fluid and install the intermediate clutch piston.
- Install the intermediate clutch return spring.
- Install the intermediate clutch return spring top plate.
- Using the special tool, install the intermediate clutch return spring retainer.
- Install the new intermediate clutch plates, starting with the wave spring then a steel plate and alternating between and fiber and steel plates, and ending with the pressure plate.
- Install the intermediate clutch plate snap ring.
- Install the intermediate clutch drum into the special tool.
- With the dial indicator 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.
- 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.
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 - 5.4L engine - 0.71-1.10 mm (0.028-0.043 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 the bearing race.
NOTE:
Before assembly, soak the new clutch plates in clean automatic transmission fluid.
NOTE:
If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.