Forward Clutch - Bonded Piston: Assembly

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.

NOTE: The special tool needs to be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.

Fig 1: Installing Special Tool On Forward Clutch Piston

Courtesy of FORD MOTOR CO.

Install the special tool on the forward clutch piston.

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

NOTE: Lubricate the forward clutch piston inner and outer seal with clean automatic transmission fluid.

Fig 2: Installing Forward Clutch Piston Assembly Into Forward Clutch Cylinder

Courtesy of FORD MOTOR CO.

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

Fig 3: Installing Forward Clutch Piston Spring Assembly
Courtesy of FORD MOTOR CO.

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

Fig 4: Installing Forward Clutch Piston Spring Retaining Ring

Courtesy of FORD MOTOR CO.

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

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 automatic transmission fluid before assembly.

Fig 5: Installing Direct Clutch Disc Pack

Courtesy of FORD MOTOR CO.

If reusing plates, grooves must be installed counterclockwise. Install the direct clutch disc pack.
Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.

Fig 6: Installing Steel Clutch Plates And Friction Clutch Plates
Courtesy of FORD MOTOR CO.

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.
  
  Fig 7: Installing Original Selective Retaining Ring
  Courtesy of FORD MOTOR CO.

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.
  
  Fig 8: Identifying Air Check Forward Clutch Piston
  Courtesy of FORD MOTOR CO.

Check forward clutch disc pack free play.

Press down on forward clutch disc pack.

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.

FORWARD CLUTCH RETAINING RING SPECIFICATIONS

Part Number	Thickness		Diameter
Part Number	mm	In	mm	In
XW4Z-7D483-AB	1.73	0.0681	141.45	5.65 in
XW4Z-7D483 -AC	2.08	0.0819	141.45	5.65 in
XW4Z-7D483 -AD	2.44	0.0961	141.45	5.65 in

Fig 9: Checking Gap Between Forward Clutch Retaining Ring And Forward Clutch Pressure Plate

Courtesy of FORD MOTOR CO.