Forward/Coast/Direct Clutches: Disassembly

Fig 1: Identifying Forward/Coast/Direct Clutches

Courtesy of FORD MOTOR CO.

1. Remove the direct clutch pressure plate retaining ring.
   Fig 2: Removing Direct Clutch Pressure Plate Retaining Ring

   Courtesy of FORD MOTOR CO.
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.
   Fig 3: Disassembling Direct Clutch Pack

   Courtesy of FORD MOTOR CO.
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.
Fig 4: Removing Direct Clutch Spring Retaining Ring
Courtesy of FORD MOTOR CO.
3. 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.
   Fig 5: Removing Direct Clutch Return Spring Assembly

   Courtesy of FORD MOTOR CO.
5. Remove the direct clutch piston assembly.
   Fig 6: Removing Direct Clutch Piston Assembly

   Courtesy of FORD MOTOR CO.
6. Remove and discard the direct clutch piston outer lip seal.
   Fig 7: Removing Direct Clutch Piston Outer Lip Seal

   Courtesy of FORD MOTOR CO.
7. Remove and discard the direct clutch piston inner lip seal from the forward/coast/direct clutch cylinder assembly.
   Fig 8: Removing Direct Clutch Piston Inner Lip Seal From The Forward/Coast/Direct Clutch Cylinder Assembly

   Courtesy of FORD MOTOR CO.
8. Remove the forward clutch pressure plate retaining ring.
   Fig 9: Removing Forward Clutch Pressure Plate Retaining Ring

   Courtesy of FORD MOTOR CO.
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.
   Fig 10: Removing Forward & Coast Clutch Plates

   Courtesy of FORD MOTOR CO.
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 return springs completely.
Fig 11: Removing Forward/Coast Clutch Return Spring Retaining Ring
Courtesy of FORD MOTOR CO.
10. 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.
    Fig 12: Removing Forward/Coast Clutch Return Spring Assembly

    Courtesy of FORD MOTOR CO.
12. Remove the forward and coast clutch pistons.
    Fig 13: Removing Forward & Coast Clutch Pistons

    Courtesy of FORD MOTOR CO.
13. Using the special tool, remove and discard the forward clutch piston inner seal from the forward/coast/direct clutch cylinder assembly.
    Fig 14: Removing Forward Clutch Piston Inner Seal From The Forward/Coast/Direct Clutch Cylinder Assembly

    Courtesy of FORD MOTOR CO.
14. Remove and discard the forward clutch piston outer lip seal.
    Fig 15: Removing Forward Clutch Piston Outer Lip Seal

    Courtesy of FORD MOTOR CO.
15. Separate the coast clutch piston assembly from the forward clutch piston assembly.
    Fig 16: Separating Coast Clutch Piston Assembly From The Forward Clutch Piston Assembly

    Courtesy of FORD MOTOR CO.
WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury.
NOTE: Do not clean the clutch plates in a vapor degreaser or in any other type of detergent solution.
16. 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