Caution: See TSB 06-14-4

Forward and Reverse Clutch Drum Assembly

1. Remove the forward clutch pressure plate snap ring.

2. Remove the forward clutch pressure plate.

3. Remove the forward clutch disc pack.

4. Remove the forward clutch spring.

5. Remove the coasting clutch pressure plate snap ring.

6. Remove the coasting clutch pressure plate.

7. Remove the coasting clutch disc pack.

8. Remove the coasting clutch piston spring.

9. Install Clutch Spring Compressor and compress the coasting clutch return spring and retainer. Remove the coasting clutch return spring snap ring.

1. Install Clutch Spring Compressor and compress the coasting clutch return spring and retainer enough to remove the coasting clutch return spring snap ring.
2. Remove the coasting clutch return spring snap ring.

10. Remove the coasting clutch return spring and retainer.

11. Remove the coasting clutch drum and the coasting clutch drum large seal from the reverse clutch drum.

1. Apply compressed air through the fluid passage. Maximum air pressure is 390 kPa (57 psi) .
2. Remove the coasting clutch drum cylinder from the reverse clutch drum.

12. Remove the coasting clutch from the coasting clutch drum.

1. Apply compressed air through the fluid passage. Maximum air pressure is 390 kPa (57 psi) .
2. Remove the coasting clutch from the coasting clutch drum.

13. Remove the reverse clutch snap ring.

14. Remove the reverse clutch pressure plate.

15. Remove the reverse clutch disc pack and the reverse clutch piston spring.

16. Use Return Spring Compressor to remove the reverse clutch piston snap ring.

1. Install Return Spring Compressor, cross bar, and plate to compress the reverse clutch pressure spring only enough to remove the reverse clutch piston snap ring.
2. Remove one end of the reverse clutch piston snap ring from the groove with snap ring pliers. Once started, remove the reverse clutch piston snap ring with a screwdriver.

17. Remove the reverse clutch spacer.

18. Remove the reverse clutch pressure spring.

19. WARNING: Use caution when using compressed air to remove components.

Remove the reverse clutch piston.

1. Place the reverse clutch on the pump assembly.
2. Apply compressed air through the fluid passage. Maximum air pressure is 390 kPa (57 psi) .
3. Remove the reverse clutch piston, the reverse clutch piston large seal, and the reverse clutch piston small 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: Clean the components with a suitable solvent and use compressed air to dry all parts and clean fluid passages. Inspect all clutches for damage and wear. Check each clutch piston and drum seal area for burrs or damage. Check for worn or broken springs.

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

1. Inspect the reverse clutch piston.

1. 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) .
2. Verify that there is no air leakage when applying compressed air through the fluid hole opposite the return spring. Apply a maximum air pressure of 390 kPa (57 psi) .

2. Apply Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the inner and outer faces of the new reverse clutch piston large seal and the reverse clutch piston small seal. Install the inner and outer seal on the reverse clutch piston.

1. Measure the reverse clutch piston large seal inner diameter, replace if needed.
2. Measure the reverse clutch piston small seal inner diameter, replace if needed.

3. Attach Low Reverse Holding Piston Seal Protector to the reverse clutch piston to install the reverse clutch piston into the reverse clutch drum.

1. Install the reverse clutch piston and Low Reverse Holding Piston Seal Protector into the reverse clutch drum.
2. Seat the reverse clutch piston by pushing evenly around the circumference of the piston. If necessary, use a screwdriver to seat the reverse clutch piston. Remove Low Reverse Holding Seal Protector.

4. Install the reverse clutch pressure spring.

• The reverse clutch pressure spring tabs face away from the reverse clutch piston.

5. Install the reverse clutch spacer. The reverse clutch spacer step faces upward.

6. Install the reverse clutch piston snap ring.

• Install the reverse clutch piston snap ring halfway down the reverse clutch drum.

7. Use Return Spring Compressor to compress the reverse clutch pressure spring and the reverse clutch spacer.

• Install the reverse clutch snap ring with a screwdriver.

8. Install the reverse clutch piston spring.

9. Install the reverse clutch disc pack.

• The installation order is steel-friction-steel-friction.

10. Install the reverse clutch pressure plate.

11. Install the reverse clutch snap ring.

12. With the reverse clutch assembled, check the reverse clutch disc pack clearance.

• Use a feeler gauge to measure the clearance between the reverse clutch pressure plate and the reverse clutch pressure plate snap ring. If the clearance is not within the specification, adjust it by selecting the proper snap ring.

13. Inspect the coasting 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. Apply a maximum air pressure of 390 kPa (57 psi) .

14. Apply the specified amount of Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the inner and outer faces of the new coasting clutch piston outer seal and the coasting clutch piston inner seal. Install the inner and outer seal on the coasting clutch drum.

1. Measure the coasting clutch piston inner seat inner diameter.
2. Measure the coasting clutch piston outer seal inner diameter.

15. Install the coasting clutch drum and the coasting clutch drum large seal, into the reverse clutch drum.

• Align the coasting clutch drum with the reverse clutch drum.

16. Apply the specified amount of Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the inner and outer faces of the new coasting clutch piston outer seal and the coasting clutch piston inner seal.

Install the inner and outer seal on the coasting clutch piston.

1. Measure the coasting clutch piston inner seal inner diameter, then install.
2. Install the coasting clutch piston inner seal.

17. Install the coasting clutch piston into the coasting clutch drum.

1. Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the coasting clutch drum.
2. Seat the coasting clutch piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.

18. Install the coasting clutch return spring and retainer.

19. Install Clutch Spring Compressor and compress the coasting clutch return spring and retainer. Install the coasting clutch return spring snap ring.

1. Install Clutch Spring Compressor and compress the coasting clutch spring and retainer enough to install the coasting clutch return spring snap ring.
2. Install the coasting clutch return spring snap ring.

20. Install the coasting clutch piston spring.

21. Install the coasting clutch disc pack.

• The installation order is steel-friction-steel-friction.

22. Install the coasting clutch pressure plate.

23. Install the coasting clutch pressure plate snap ring.

24. With the coasting clutch assembled, check the coasting clutch disc pack clearance.

• Use a feeler gauge to measure between the coasting clutch pressure plate and the coasting clutch pressure plate snap ring. The clearance should be 1.0 - 1.2 mm (0.039 - 0.047 inch) . If the clearance is not within the specification, adjust it by selecting the proper snap ring.

25. Install the forward clutch spring.

26. Install the forward clutch disc pack.

• The installation order is steel-friction- steel -friction- steel -friction.

27. Install the forward clutch pressure plate.

28. Install the forward clutch pressure plate snap ring.

29. With the forward clutch assembled, check the forward clutch disc pack clearance.

1. Use a feeler gauge to measure between the forward clutch pressure plate and the forward clutch pressure plate snap ring. The clearance should be 1.0 - 1.2 mm (0.039 - 0.047 inch) . If the clearance is not within the specification, adjust it by selecting the proper snap ring.

30. NOTE: To check the clutch operation, apply a maximum air pressure of 390 kPa (57 psi) .

Check each clutch operation after assembly.

1. Position the clutch assembly onto the pump.
2. Check the forward clutch operation by applying compressed air to the forward clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.
3. Check the reverse clutch operation by applying compressed air to the reverse clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.
4. Check the coasting clutch operation by applying compressed air to the coasting clutch hole at the pump. The clutch should make a solid apply sound, with no whistle or signs of leakage.