Forward/Coast/Direct Clutches

NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.

Special Tools:

1 Of 2:

2 Of 2:

Disassembly





1. Remove the direct clutch pressure plate retaining ring.





2. Disassemble the direct clutch pack.
1 Remove the direct clutch pressure plate.
2 Remove the direct clutch steel plates.
3 Remove the direct clutch friction plates.





3. CAUTION: Do not compress the direct clutch return springs completely.

Remove the direct clutch spring retaining ring.
1 Using the special tool, compress the direct clutch return springs.
2 Remove the direct clutch return spring retaining ring.





4. Remove the direct clutch return spring assembly.





5. Remove the direct clutch piston assembly.





6. Remove and discard the direct clutch piston outer lip seal.





7. Remove and discard the direct clutch piston inner lip seal from the forward/coast/direct clutch cylinder assembly.





8. Turn the forward/coast/direct clutch cylinder assembly over and remove the forward clutch pressure plate retaining ring.





9. Remove the forward and coast clutch plates.
1 Forward Clutch Pressure Plate
2 Forward Clutch External Spline Clutch Plates (Steel)
3 Coast Clutch Internal Spline Clutch Plates (Friction)
4 Coast Clutch External Spline Clutch Plates (Steel)
5 Coast Clutch Pressure Plate
6 Forward Clutch Internal Spline Clutch Plates (Friction)
7 Forward Clutch Wave Spring





10. CAUTION: Do not compress the return springs completely.

Remove the forward/coast clutch return spring retaining ring.
1 Using the special tool, compress the return spring.
2 Remove the retaining ring.





11. Remove the forward/coast clutch return spring assy.





12. Remove the forward and coast clutch pistons.





13. Using the special tool, remove and discard the forward clutch piston inner seal from the forward/coast/direct clutch cylinder assembly.





14. Remove and discard the forward clutch piston outer lip seal.





15. Separate the coast clutch piston assembly with integral seal from the forward clutch piston assembly.

16. NOTE: Do not clean the clutch plates in a vapor degreaser or in any other type of detergent solution.

Clean all parts thoroughly in a clean solvent and blow dry with moisture-free regulated compressed air.
^ Clean the clutch plates with a lint-free cloth.
^ Soak the new clutch plates in the specified transmission fluid for l 5 minutes before assembly.
17. Inspect the parts for damage or wear.
^ Spline teeth
^ Clutch plates
^ Seals
^ Bushing
^ Check balls in pistons
^ Piston bore
^ Passages and lubrication holes in the forward/coast/direct clutch cylinder.

Assembly
1. Soak the internal spline clutch plates in clean Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification for 15 minutes before assembly.





2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.





3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.





5. Using the special tool, install the coast clutch piston assembly.





6. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.





7. Install the forward/coast clutch return spring assembly.





8. CAUTION: Do not compress the return springs completely.

Install the forward/coast clutch return spring retaining ring.
1 Using the special tool compress the return spring.
2 Install the forward/coast clutch retaining ring.





9. Install the forward and coast clutch plates.
1 Forward clutch pressure plate
2 Forward clutch external spline clutch plates (steel)
3 Coast clutch internal spline clutch plates (friction)
4 Coast clutch external spline clutch plates (steel)
5 Coast clutch pressure plate
6 Forward clutch internal spline clutch plates (friction)
7 Forward clutch wave spring





10. Install the forward clutch pressure plate retaining ring.





11. Measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring with a feeler gauge.
^ Take a second measurement on the opposite side.
^ Average the two measurements to get the clearance.
^ If the clearance is not within specification, select and install the proper thickness retaining ring to obtain the standard clearance.
^ Retaining ring sizes:
^ 1.43-1.53 mm
^ 1.59-1.69 mm
^ 1.75-1.85 mm
^ 1.92-2.02 mm





12. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.





13. Install the direct clutch piston outer seal on the direct clutch piston assembly.





14. NOTE: Position the lip seal facing down.

Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.





15. Install the direct clutch return spring assembly.





16. CAUTION: Do not compress the direct clutch return springs completely.

Install the direct clutch return spring retaining ring.
1 Using the special tool, compress the direct clutch return springs.
2 Install the direct clutch return spring retaining ring.





17. Install the direct clutch plates.
1 Install the direct clutch external spline (steel) clutch plates.
2 Install the direct clutch internal spline (friction) clutch plates.
3 Install the direct clutch pressure plate.





18. Install the direct clutch pressure plate retaining ring.





19. Measure the direct clutch clearance as follows:
^ Install the special tool.
^ Zero the dial on the direct clutch pressure plate.
^ Pull the direct clutch pressure plate upward, and record the reading.





20. Make a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within the specification, select and install, using the special tool, the correct thickness direct clutch pressure plate retainer snap ring to obtain the standard clearance.
Retaining ring sizes:
^ 1.28-1.38 mm
^ 1.39-1.49 mm
^ 1.52-1.62 mm
^ 1.65-1.75 mm