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Direct Clutch Drum Assembly: Material

MATERIAL SPECIFICATION

Item Specification
MERCON® V Automatic Transmission Fluid XT-5-QM MERCON® V
NOTE: Inspect the clutch components for damage or wear. Install new components as necessary.
  • Inspect the drum surface for damage.
  • Inspect the clutch piston bore, and piston.
  • 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.
  1. Disassemble the parts in the order indicated in Fig 1.
    Fig 1: Direct Clutch Drum Assembly Disassembly Sequence
    G03281680Courtesy of FORD MOTOR CO.
  2. To assemble, reverse the disassembly procedure.

Item 5: Retaining Ring Disassembly Note 

    WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.
    CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.
    Fig 2: Removing Direct Clutch Piston Retaining Ring
    G03281681Courtesy of FORD MOTOR CO.
  1. Using the special tool, remove the direct clutch piston retaining ring.

Item 8: Direct and Overdrive Clutch Piston Disassembly Note 

    WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure the drum is facing down as shown. Failure to follow these instructions may result in personal injury.
    Fig 3: Removing Direct Clutch Piston
    G03281682Courtesy of FORD MOTOR CO.
  1. Using compressed air, remove the direct clutch piston from the direct clutch drum.
    • Apply air pressure to the hole in the drum while blocking the other hole with a finger.

Item 11: Intermediate Brake Drum Assembly Note 

  1. Verify the check ball is free to move.
    Fig 4: Identifying Ball Position
    G03281683Courtesy of FORD MOTOR CO.

Items 9 and 10: Direct and Overdrive Piston Outer and Inner Seal Ring Assembly Note 

    CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
    NOTE: Use new seals to help prevent seal failures.
    Fig 5: Installing New Direct Clutch Piston Inner Seal And Direct Clutch Piston Outer Seal
    G03281684Courtesy of FORD MOTOR CO.
  1. Lubricate the seals, then install the new direct clutch piston inner seal and the direct clutch piston outer seal.
    2. CAUTION: Care must be taken to prevent damage to the seals during installation.
    Fig 6: Installing Direct Clutch Piston
    G03281685Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the direct clutch piston.

Item 5: Retaining Ring Assembly Note 

    WARNING: After removing the retaining ring, use care when releasing the pressure on the springs. Failure to follow these instructions may result in personal injury.
    CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.
    Fig 7: Installing Direct Clutch Piston Retaining Ring
    G03281686Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the direct clutch piston retaining ring.

Items 4 and 3: Direct Clutch Internal/External Splined Friction Plate Assembly Note 

    CAUTION: The direct clutch friction plates are directional and must be installed correctly. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates.
    CAUTION: If new plates are used, they should be soaked in clean automatic transmission fluid before assembly.
    Fig 8: Installing Direct Clutch Disc Pack
    G03281687Courtesy of FORD MOTOR CO.
  1. When installing friction plates, alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates. Install the direct clutch disc pack.
  2. Install the friction plates. Alternate the internally splined (clockwise) and the externally splined (counterclockwise) clutch plates starting with an externally splined (counterclockwise) clutch plate.
    Fig 9: Installing Friction Plates
    G03281688Courtesy of FORD MOTOR CO.

Item 1: Retaining Ring Assembly Note 

    WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air, and make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.
    Fig 10: Air Checking Assembly
    G03281689Courtesy of FORD MOTOR CO.
  1. Air check the assembly.
    • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
  2. Push down on direct clutch disc pack and check gap between the direct clutch retaining ring and the direct clutch pressure plate with a feeler gauge.
    • If specifications do not match, use a select fit direct clutch retaining ring to match specifications and verify with a feeler gauge.

    Direct Clutch 

    DIRECT CLUTCH RETAINING RING THICKNESS SPECIFICATIONS

    Part Number Thickness Diameter
    mm In mm In
    E860126-S 1.37 0.0539 130.1 5.122
    E860127-S 1.73 0.0681 130.1 5.122
    E860128-S 2.08 0.0819 130.1 5.122
    E860129-S 2.44 0.0961 130.1 5.122
    Fig 11: Checking Gap Between Direct Clutch Retaining Ring And Direct Clutch Pressure Plate
    G03281690Courtesy of FORD MOTOR CO.
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