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Home › Ford › 2001 › Escape 3.0 1, FWD › Repair and Diagnosis › Transmission › Automatic Trans › Overhaul- Automatic Transmission › Disassembly & Assembly Of Subassemblies › Forward/Coast/Direct Clutches › Assembly

Forward/Coast/Direct Clutches: Assembly

  1. Soak the internal spline clutch plates in clean automatic transmission fluid.
  2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.
    Fig 1: Installing Forward Clutch Piston Inner Seal On The Forward/Coast/Direct Clutch Cylinder Assembly
    G02050609Courtesy of FORD MOTOR CO.
  3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
    Fig 2: Installing Forward Clutch Piston Outer Lip Seal On The Forward Clutch Piston Assembly
    G02050610Courtesy of FORD MOTOR CO.
  4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
    Fig 3: Installing Forward Clutch Piston Assembly In The Forward/Coast/Direct Clutch Cylinder Assembly
    G02050611Courtesy of FORD MOTOR CO.
  5. Mark the center of two adjacent legs on the top of the cylinder.
    Fig 4: Marking Center Of Two Adjacent Legs On The Top Of The Cylinder
    G02050612Courtesy of FORD MOTOR CO.
  6. Find the center between the marks (45 degrees from either leg) and mark the cylinder.
    Fig 5: Finding Center Between The Marks & Marking The Cylinder
    G02050613Courtesy of FORD MOTOR CO.
  7. Install the coast clutch piston assembly onto the special tool.
    Fig 6: Installing Coast Clutch Piston Assembly Onto The Special Tool
    G02050614Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.
    Fig 7: Installing Coast Clutch Piston Into The Forward Clutch Piston Assembly
    G02050615Courtesy of FORD MOTOR CO.
  9. Install the forward/coast clutch return spring assembly.
    Fig 8: Installing Forward/Coast Clutch Return Spring Assembly
    G02050616Courtesy of FORD MOTOR CO.
    10. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
    Fig 9: Installing Forward/Coast Clutch Return Spring Retaining Ring
    G02050617Courtesy of FORD MOTOR CO.
  10. 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.
    • Orient 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.
    Fig 10: Installing Forward & Coast Clutch Plates
    G02050618Courtesy of FORD MOTOR CO.
  12. Install the forward clutch pressure plate retaining ring.
    • Center the select fit retaining ring on the 45-degree mark between the two adjacent legs.
    Fig 11: Installing Forward Clutch Pressure Plate Retaining Ring
    G02050619Courtesy of FORD MOTOR CO.
  13. Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring.
    • 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 correct thickness retaining ring to obtain the standard clearance.
    • Retaining ring sizes:
      • 1.43-1.53 mm (0.056-0.060 in)
      • 1.59-1.69 mm (0.062-0.066 in)
      • 1.75-1.85 mm (0.069-0.073 in)
      • 1.92-2.02 mm (0.075-0.079 in)
    Fig 12: Measuring Clearance Between Forward Clutch Pressure Plate & Forward Clutch Pressure Plate Retaining Ring
    G02050620Courtesy of FORD MOTOR CO.
  14. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.
    Fig 13: Installing Direct Clutch Piston Inner Lip Seal On The Direct Clutch Cylinder Assembly
    G02050621Courtesy of FORD MOTOR CO.
  15. Install the direct clutch piston outer seal on the direct clutch piston assembly.
    Fig 14: Installing Direct Clutch Piston Outer Seal On The Direct Clutch Piston Assembly
    G02050622Courtesy of FORD MOTOR CO.
    16. NOTE: Position the lip seal facing down.
    Fig 15: Installing Direct Clutch Piston Assembly In The Forward/Coast/Direct Clutch Cylinder Assembly
    G02050623Courtesy of FORD MOTOR CO.
  16. Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
  17. Install the direct clutch return spring assembly.
    Fig 16: Installing Direct Clutch Return Spring Assembly
    G02050624Courtesy of FORD MOTOR CO.
    18. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
    CAUTION: Do not  compress the direct clutch return springs completely.
    Fig 17: Installing Direct Clutch Return Spring Retaining Ring
    G02050625Courtesy of FORD MOTOR CO.
  18. 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. NOTE: Quantity of plates are model dependent.
    Fig 18: Installing Direct Clutch Plates
    G02050626Courtesy of FORD MOTOR CO.
  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.
    Fig 19: Installing Direct Clutch Pressure Plate Retaining Ring
    G02050627Courtesy of FORD MOTOR CO.
  21. 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.
    Fig 20: Measuring Direct Clutch Clearance
    G02050628Courtesy of FORD MOTOR CO.
  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 in)
      • 1.39-1.49 mm (0.054-0.058 in)
      • 1.52-1.62 mm (0.059-0.063 in)
      • 1.65-1.75 mm (0.064-0.069 in)
    Fig 21: Installing Direct Clutch Pressure Plate Retainer Snap Ring
    G02050629Courtesy of FORD MOTOR CO.
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