Direct Clutch Assembly: Assembly

NOTE: Early production direct clutch cylinder hub has 24 spline teeth and must be serviced with 24 spline friction plates. The late production direct clutch cylinder hub has 96 spline teeth and must be serviced with 96 spline friction plates. If a new direct clutch cylinder is needed, the service part will have 96 splines, and a 96 spline friction plate must be used with it as a set.

Inspect the direct clutch cylinder.
1. The early production vehicles will have a 24 tooth direct clutch cylinder.
2. The late production vehicles will have a 96 tooth direct clutch cylinder.
  
  Fig 1: Inspecting Direct Clutch Cylinder
  Courtesy of FORD MOTOR CO.
Lightly lubricate the new pistons with clean automatic transmission fluid.
1. Direct clutch piston
2. Direct clutch return spring
3. Direct clutch balance piston
  
  Fig 2: Cleaning Automatic Transmission Fluid
  Courtesy of FORD MOTOR CO.
Install a new direct clutch piston.

Fig 3: Installing A New Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Install the direct clutch return spring and a new balance piston.

Fig 4: Installing Direct Clutch Return Spring And A New Balance Piston
Courtesy of FORD MOTOR CO.
Using the special tools, install the snap ring.

Fig 5: Installing Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: The direct clutch plates are installed in an alternating sequence, starting with an externally splined steel plate, then an internally splined friction plate, with the pressure plate on the top just under the snap ring.

Install the plates.
1. Externally splined steel plates
2. Internally splined friction plates
3. Pressure plate
  
  Fig 6: Identifying Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 7: Installing Snap Ring
Courtesy of FORD MOTOR CO.
Using a feeler gauge, measure the clearance between the snap ring and the pressure plate.

Fig 8: Measuring Clearance Between Snap Ring And Pressure Plate
Courtesy of FORD MOTOR CO.