Direct Clutch

Special Tools:

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY
1. Remove the thrust bearing.





2. Remove the direct clutch pressure plate snap ring.





3. Remove the direct clutch pressure plate.





4. Remove the direct clutch disc pack.





5. Use Clutch Spring Compressor to remove the direct clutch return spring snap ring.
1 Install Clutch Spring Compressor and compress the direct clutch piston spring. Compress the direct clutch piston spring only enough to remove the snap ring.
2 Remove the direct clutch return spring snap ring.





6. Remove the (A) direct clutch piston spring retainer and the (B) direct clutch piston spring.





7. Use Leak Check Adapter to remove the direct clutch piston.
1 Install Leak Check Adapter to the direct clutch cylinder.
2 Apply compressed air through Leak Check Adapter and remove the direct clutch piston. Apply a maximum air pressure of 390 kPa (57 psi).





8. Remove the (A) direct clutch piston large seal and the (B) direct clutch piston inner seal.

ASSEMBLY

CAUTION: Composition clutch plates and synthetic seals should not be cleaned in a vapor degreaser or with any type of detergent cleaner. To clean these parts, wipe them off with a lint free cloth. New clutch plates or bands should be soaked in Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON for two hours before being assembled. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.

NOTE: Clutch clearances are adjusted by the selection of snap ring thickness. If the clearance is not within specification, adjust as necessary.

1. Clean the components with a suitable solvent and use compressed air to dry all parts and clean the fluid passages. Perform the following before assembly:
^ Inspect the clutch cylinder damage or wear.
^ Inspect all clutches for damage or wear.
^ Check the clutch piston and drum seal area for burrs or damage.





2. Measure the direct drive plate facing thickness.
^ If not within the specification, replace the drive plates.

NOTE: Measure the facing thickness in three places and calculate the average value.





3. Measure the direct clutch piston spring free length.
^ If not within the specification, replace the direct clutch piston spring.

NOTE: Do not compress the direct clutch piston spring when measuring it with vernier calipers.





4. Inspect the direct clutch piston.
^ Verify that there is air flow when applying compressed air through the fluid hole on the return spring side. Apply a maximum air pressure of 390 kPa (57 psi).
^ Verify that there is no air leakage when applying compressed air through the fluid hole opposite the return spring side. Apply a maximum air pressure of 390 kPa (57 psi).





5. Apply Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the direct clutch piston large seal and the direct clutch piston inner seal and install the (A) direct clutch piston large seal and the (B) direct clutch piston inner seal.





6. Measure the inner diameters of the direct clutch piston large seal and the direct clutch piston inner seal.
^ Replace if not within specification.





7. Install the direct clutch piston into the direct clutch cylinder. Seat the direct clutch piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.





8. Install the (A) direct clutch piston spring retainer and the (B) direct clutch piston spring.





9. Use Clutch Spring Compressor to install the direct clutch return spring snap ring.
1 Install Clutch Spring Compressor and compress the direct clutch piston spring. Compress the direct clutch piston spring only enough to install the direct clutch return spring snap ring.
2 Install the direct clutch return spring snap ring.





10. Install the direct clutch disc pack.
^ The installation order is alternating steel-friction-steel-friction, etc.





11. Install the direct clutch pressure plate.





12. Install the direct clutch pressure plate snap ring.








13. With the direct clutch assembled, check the direct clutch disc pack clearance.
1 Use a feeler gauge to measure between the direct clutch pressure plate and the direct clutch pressure plate snap ring. The clearance should be 1.3 - 1.6 mm (0.051 - 0.063 inch). If the clearance is not within the specification, adjust it by selecting the proper snap ring.





14. Use Leak Check Adapter to check the direct clutch piston operation.
1 Install Leak Check Adapter to the direct clutch cylinder.
2 Apply compressed air through Leak Check Adapter. Apply a maximum air pressure of 390 kPa (57 psi). The direct clutch should make a solid apply sound.





15. Pour Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON into the direct clutch cylinder until the direct clutch piston is submerged. Apply compressed air through Leak Check Adapter. Apply a maximum air pressure of 390 kPa (57 psi). Verify that no bubbles come from the direct clutch piston seals.





16. Apply petroleum jelly to the thrust bearings and install them on the direct clutch cylinder.
^ The thrust bearing outer diameter for the carrier hub side should be 56.1 mm (2.21 inch). The thrust bearing outer diameter for the output shell side should be 72.1 mm (2.84 inch).