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Home › Ford › 2000 › ZX2 Automatic › Repair and Diagnosis › External Pages › Different car › Section 1411 (Automatic Transmission - 6F35) › Disassembly And Assembly Of Subassemblies › Overdrive/Direct Clutch Assembly › Disassembly

Overdrive/Direct Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the input shaft snap ring.
    Fig 1: Locating Input Shaft Snap Ring
    G06377219Courtesy of FORD MOTOR CO.
  2. Remove the input shaft.
    Fig 2: Locating Input Shaft
    G06377220Courtesy of FORD MOTOR CO.
  3. Remove the Overdrive (O/D) (4, 5, 6) clutch hub.
    Fig 3: Locating Overdrive (O/D) (4, 5, 6) Clutch Hub
    G06377221Courtesy of FORD MOTOR CO.
  4. Remove the O/D  (4, 5, 6) clutch hub, No. 2 thrust bearing.
    Fig 4: Locating No. 2 Thrust Bearing
    G06377222Courtesy of FORD MOTOR CO.
  5. Remove the O/D  (4, 5, 6) clutch snap ring.
    Fig 5: Locating O/D (4, 5, 6) Clutch Snap Ring
    G06377223Courtesy of FORD MOTOR CO.
  6. Remove the O/D  (4, 5, 6) clutch pressure plate and clutch assembly.
    Fig 6: Locating O/D (4, 5, 6) Clutch Pressure Plate
    G06377224Courtesy of FORD MOTOR CO.
  7. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2 on the balance piston.
    Fig 7: Identifying Special Tools (307-589/1) And (307-584/2)
    G06377225Courtesy of FORD MOTOR CO.
  8. Using a press, compress the O/D  (4, 5, 6) clutch return spring and remove the snap ring.
    Fig 8: Locating Snap Ring
    G06377226Courtesy of FORD MOTOR CO.
  9. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/1 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 9: Identifying Special Tools (307-589/1) And (307-584/2)
    G06377227Courtesy of FORD MOTOR CO.
  10. Remove and discard the balance piston.
    Fig 10: Locating Balance Piston
    G06377228Courtesy of FORD MOTOR CO.
  11. Remove the O/D  (4, 5, 6) piston return spring.
    Fig 11: Locating O/D (4, 5, 6) Piston Return Spring
    G06377229Courtesy of FORD MOTOR CO.
  12. Install the clutch support tower in the transmission case and install the 3 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 12: Locating Clutch Support Tower
      G06377230Courtesy of FORD MOTOR CO.
  13. Remove the Input Shaft Support Seal Installer 307-578/1 (sizer).
    Fig 13: Identifying Input Shaft Support Seal Installer (307-578/1)
    G06377231Courtesy of FORD MOTOR CO.
  14. Install the No. 1 O/D  /direct clutch assembly thrust bearing.
    Fig 14: Locating No. 1 O/D /Direct Clutch Assembly Thrust Bearing
    G06377232Courtesy of FORD MOTOR CO.
  15. Position the O/D  /direct clutch assembly in the transaxle case.
    Fig 15: Identifying Direct Clutch Assembly
    G06377233Courtesy of FORD MOTOR CO.
  16. Apply compressed air to the O/D  (4, 5, 6) clutch piston port and remove the O/D  (4, 5, 6) clutch piston.
    Fig 16: Removing O/D (4, 5, 6) Clutch Piston
    G06377234Courtesy of FORD MOTOR CO.
  17. Remove the O/D  /direct clutch assembly from the transaxle case.
    Fig 17: Identifying Direct Clutch Assembly
    G06377235Courtesy of FORD MOTOR CO.
  18. Remove the O/D  (4, 5, 6) clutch piston seal from the O/D  /direct clutch assembly.
    Fig 18: Removing O/D (4, 5, 6) Clutch Piston Seal From Direct Clutch Assembly
    G06377236Courtesy of FORD MOTOR CO.
  19. Remove the 2 seals from the O/D  (4, 5, 6) clutch piston.
    Fig 19: Removing Seals From O/D (4, 5, 6) Clutch Piston
    G06377237Courtesy of FORD MOTOR CO.
    20. NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
  20. Install the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2 on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.
    1. Do not contact the O/D  /direct clutch hub and shaft assembly with the direct (3, 5, R) clutch cylinder.
    2. Remove the snap ring.
      Fig 20: Identifying Special Tools (307-589/2) And (307-584/2) On Direct (3, 5, R) Clutch Cylinder
      G06377238Courtesy of FORD MOTOR CO.
  21. Remove the Overdrive Clutch, Balance Piston and Direct Clutch Compressor 307-589/2 and Forward/Intermediate Spring Compressor 307-584/2.
    Fig 21: Identifying Special Tools (307-589/2) And (307-584/2)
    G06377239Courtesy of FORD MOTOR CO.
  22. Remove the direct (3, 5, R) clutch cylinder.
    Fig 22: Removing Direct (3, 5, R) Clutch Cylinder
    G06377240Courtesy of FORD MOTOR CO.
  23. Remove and discard the direct (3, 5, R) clutch piston.
    Fig 23: Removing Direct (3, 5, R) Clutch Piston
    G06377241Courtesy of FORD MOTOR CO.
    24. NOTE: Note the position of the return spring for assembly. The flat side faces down.
    Fig 24: Locating Direct (3, 5, R) Clutch Piston Return Spring
    G06377242Courtesy of FORD MOTOR CO.
  24. Remove the direct (3, 5, R) clutch piston return spring.
  25. Remove the direct (3, 5, R) clutch snap ring.
    1. Slightly lift up on the direct (3, 5, R) clutch so that the snap ring floats freely.
    2. Using a suitable tool, compress the snap ring.
    3. Allow the direct (3, 5, R) clutch and pressure plate to drop so that the snap ring is out of the pressure plate groove.
    4. Remove the snap ring.
      Fig 25: Removing Direct (3, 5, R) Clutch Snap Ring
      G06377243Courtesy of FORD MOTOR CO.
  26. Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.
    Fig 26: Locating Direct (3, 5, R) Clutch Assembly And Pressure Plate
    G06377244Courtesy of FORD MOTOR CO.
  27. Remove and discard the 3 direct (3, 5, R) clutch piston seals.
    Fig 27: Removing Direct (3, 5, R) Clutch Piston Seals
    G06377245Courtesy of FORD MOTOR CO.
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