LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Mercury >> 2002 >> Villager Base >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> 3-4 Clutch >> Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

3-4 Clutch: Assembly

  1. Install new 3-4 clutch piston seals.
    • Coat the seals with Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON® prior to installation.
      Fig 1: Installing 3-4 Clutch Piston Seals
      G03412525Courtesy of FORD MOTOR CO.
  2. Install the 3-4 clutch piston.
    1. Coat the 3-4 clutch drum and input shaft with Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON®.
    2. Install the clutch piston.
      Fig 2: Installing 3-4 Clutch Piston
      G03412526Courtesy of FORD MOTOR CO.
  3. Install the 3-4 clutch piston spring retainer assembly.
    1. Install the springs.
    2. Install the spring retainer.
      Fig 3: Installing Springs
      G03412527Courtesy of FORD MOTOR CO.
  4. Install the 3-4 clutch snap ring.
    1. Using the special tool, compress the clutch piston.
    2. Install the snap ring.
      Fig 4: Installing 3-4 Clutch Snap Ring
      G03412528Courtesy of FORD MOTOR CO.
  5. Install the 3-4 clutch pack.
    Fig 5: Installing 3-4 Clutch Pack
    G03412529Courtesy of FORD MOTOR CO.
  6. Install the 3-4 clutch pack snap ring.
    Fig 6: Installing 3-4 Clutch Pack Snap Ring
    G03412530Courtesy of FORD MOTOR CO.
  7. Measure the clearance between the 3-4 clutch snap ring and the pressure plate.
    Fig 7: Measuring Clearance Between 3-4 Clutch Snap Ring And Pressure Plate
    G03412531Courtesy of FORD MOTOR CO.
  8. The standard clearance for the 3-4 clutch pack is 1.8 -2.2 mm (0.071-0.087 in). The maximum clearance for the pack is 3.0 mm (0.12 in). If the clearance is greater than 3.0 mm (0.118 in), select and install the correct thickness pressure plate.
    3-4 CLUTCH PRESSURE PLATE THICKNESS SPECIFICATION

    Thickness Part Number
    3.0 mm (0.118 in) F3XY-7B066-N
    3.2 mm (0.126 in) F3XY-7BO66-AAA
    3.4 mm (0.134 in) F3XY-7B066-P
    3.6 mm (0.142 in) F3XY-7B066-Q
    3.8 mm (0.150 in) F3XY-7B066-R
  9. Use compressed air to check the operation of the 3-4 clutch pack.
    Fig 8: Using Compressed Air To Check Operation Of 3-4 Clutch Pack
    G03412532Courtesy of FORD MOTOR CO.
    10. CAUTION: Be sure to unwrap the input shaft seals prior to transaxle assembly.
    Fig 9: Identifying Input Shaft Seals
    G03412533Courtesy of FORD MOTOR CO.
  10. Wrap input shaft seals to prevent them from spreading prior to transaxle assembly.
scientia non olet · About LEMON Manuals