Forward Clutch

Special Tools:

Forward Clutch Assembly

Disassembly





1. Remove the pressure plate.
1 Remove the forward clutch retaining ring.
2 Remove the pressure plate.





2. Remove the forward clutch disc pack.
- Inspect the forward clutch plates for wear, damage or overheating.

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 fully depress the special tool or damage to the spring retainer may occur.





Using the special tool, remove the forward clutch piston retaining ring.
4. Relieve the forward clutch spring tension and remove the tool.
5. Remove the forward clutch piston spring retainer, springs, and cushion spring.





1 Remove the forward clutch piston spring retainer.
2 Remove the forward clutch piston springs.
- Inspect the forward clutch piston springs for distortion.

6. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.

Remove the forward clutch piston.





1 Place the forward clutch cylinder with forward clutch piston facing down.
2 Install the center support on the forward clutch cylinder.
3 Apply air pressure to the left port of the center support.





7. Remove the cushion spring.





8. Remove and discard the forward clutch piston seals.
- Inspect the forward clutch piston for cracks.
9. Inspect the forward clutch drum assembly.





1 Inspect the forward clutch cylinder surfaces for scores or burrs.
2 Inspect forward clutch piston for scores or burrs.
3 Verify the check ball is free to move in the piston.

Assembly
1. Inspect the clutch components for damage or wear. Install new components as necessary.
- Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
- Inspect the clutch plates for damage.
- Inspect the clutch springs.
- Inspect the needle bearing and seal rings for damage.
- Check clutch hub thrust surfaces for damage.
- Check clutch plates for flatness and fit on the clutch hub serrations.





2. Install new forward clutch piston seals.

3. CAUTION: Care must be taken to prevent damage to the seals.

Note: Lubricate the forward clutch piston inner and outer seal with MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V.





Using the special tool, install the forward clutch piston into the forward clutch cylinder.
4. Install the forward clutch piston spring retainer.





1 Install the forward clutch piston spring.
2 Install the forward clutch piston spring retainer.

5. CAUTION: Do not fully depress the clutch spring compressor or damage to the spring retainer may occur.





Using the special tool, install the forward clutch piston spring retaining ring.

6. CAUTION: If there is evidence of clutch plate burning, install a new forward clutch cushion.





Install the forward clutch cushion spring.

CAUTION: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise.

CAUTION: If new plates are used, they should be soaked in clean MERCON(V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification PERSONS V for at least 30 minutes before assembly.





If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.





8. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.

9. CAUTION: The retaining ring is a select fit.





Install the original selective retaining ring.
1 Install the forward clutch pressure plate.
2 Install the original selective retaining ring.

10. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure the cylinder is facing down as shown. Failure to follow these instructions may result in personal injury.





Air check the forward clutch piston.
1 Place the forward clutch cylinder with forward clutch piston facing down.
2 Install the transmission center support on the forward clutch cylinder.
3 Apply air pressure to the left port of the center support.
11. Check forward clutch disc pack free play.





1 Press down on forward clutch disc pack.
2 Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.





- If the clearance is not within specifications, install the correct size retaining ring.