Direct Clutch Cylinder: Assembly

NOTE: The lip on the seal must face toward the bottom of the clutch cylinder.

Fig 1: Installing Inner Piston Seal

Courtesy of FORD MOTOR CO.

Install the inner piston seal.
Install the direct clutch piston into the special tool.

Fig 2: Installing Direct Clutch Piston Into Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Make sure that the check ball is in place on the clutch piston. Lightly coat all the seals with petroleum jelly prior to installation.

Fig 3: Installing Clutch Piston And Seal Assembly

Courtesy of FORD MOTOR CO.

Using the special tool, install the clutch piston and seal assembly making sure that it is fully seated.
Install the apply ring.

Fig 4: Installing Apply Ring
Courtesy of FORD MOTOR CO.

NOTE: The notch on the direct clutch return spring must line up with the check ball on the direct clutch piston.

Fig 5: Installing Direct Clutch Return Spring

Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the Clutch Spring Compressor to bottom out on the piston.

Fig 6: Installing Snap Ring

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CAUTION: Check for wear on the inner splines of the friction plates. Install new plates if worn.

Install the intermediate clutch pack.
1. Install the intermediate clutch pack.
2. Install the clutch pressure plate.
3. Install the snap ring.
  
  Fig 7: Installing Intermediate Clutch Pack
  Courtesy of FORD MOTOR CO.
Using the special tool, measure the clearance between the retaining ring and the clutch cylinder lip.

Fig 8: Measuring Clearance Between Retaining Ring And Clutch Cylinder Lip
Courtesy of FORD MOTOR CO.
If the clearance is not within specification, selective retaining rings are available. Check the clearance after installing the correct selective retaining ring.

Fig 9: Selective Retaining Ring Specification Table
Courtesy of FORD MOTOR CO.