Forward/Coast/Direct Clutches

Forward/Coast/Direct Clutches

Special Tools





Part 1 of 2





Part 2 of 2








Step 1 - 2





Step 3 - 25

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. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.

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. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.

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 assembly.





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 from the forward clutch piston assembly.

16. WARNING: Air pressure must not exceed 1.38 bar (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions may result in personal injury.

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 steel clutch plates with a lint-free cloth.
^ Soak the new clutch plates in the specified transmission fluid for 30 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.


See TSB 06-14-4

Assembly
1. Soak the internal spline clutch plates in clean Motorcraft MERCON(R)) Multi-purpose automatic transmission fluid or equivalent meeting MERCON(R) specification for 30 minutes before assembly. MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.





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. NOTE: The select tit retaining ring must be centered between two adjacent legs.

Using a felt tip marker (do not use a paint pen) mark the center of two adjacent legs on the top of the cylinder.





6. Using a felt tip marker (do not use a paint pen) mark the cylinder at the center point between the marks on the two adjacent legs.





7. Install the coast clutch piston assembly onto the special tool.





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





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





10. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.

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.
^ Align the gap between the piston legs.





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





12. Position the select fit retaining ring on the center mark between the two adjacent legs.





13. 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 (0.056 - 0.060 inch)
- 1.59 - 1.69 mm (0.063 - 0.067 inch)
- 1.75 - 1.85 mm (0.069 - 0.073 inch)
- 1.92 - 2.02 mm (0.076 - 0.080 inch)





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





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





16. NOTE: Position the lip seal facing down.

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





17. Install the direct clutch return spring assembly.





18. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.

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.





19. 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.





20. Install the direct clutch pressure plate retaining ring.





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





22. 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 (0.050 - 0.054 inch)
- 1.39 - 1.49 mm (0.055 - 0.059 inch)
- 1.52 - 1.62 mm (0.060 - 0.063 inch)
- 1.65 - 1.75 mm (0.065 - 0.069 inch)