Removal And Installation: Clutch: Installation

If installing a new clutch go to step 19.
NOTE: Make sure the special tool washer is also installed.

Install the special tool in a vise.

Fig 1: Installing Special Tool Into Vise
Courtesy of FORD MOTOR CO.
Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.

Fig 2: Aligning Clutch Stud With Slotted Hole On Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool loosely on the clutch.

Fig 3: Installing Special Tool On Clutch
Courtesy of FORD MOTOR CO.
Install the special tool on the clutch making sure the legs are inserted in the slots.

Fig 4: Installing Special Tool On Clutch Properly
Courtesy of FORD MOTOR CO.
Turn the special tool clockwise to the stops and hold.

Fig 5: Turning Special Tool Clockwise
Courtesy of FORD MOTOR CO.
NOTE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.

Fig 6: Locking Clutch And Lock Using Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool loosely on the clutch.

Fig 7: Installing Special Tool On Clutch
Courtesy of FORD MOTOR CO.
Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.

Fig 8: Moving Clutch Self-Adjuster Counterclockwise Using Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Make sure the clutch self-adjuster is held to the stops before compressing the clutch or damage will occur to the clutch.

NOTE: An audible click can be heard when the clutch locks lock.

While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to the stops on the clutch. The locks on clutch 2 lock at this time.

Fig 9: Compressing Clutch Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 10: Removing Special Tools
Courtesy of FORD MOTOR CO.
NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as shown in illustration. If not, reset the clutch 2 locks as necessary.

Visually check the locks to make sure they have locked. 4 locks shown in illustration, 12 total.

Fig 11: Locating Aligning Position Of Locked Clutch Fingers And Clutch Studs
Courtesy of FORD MOTOR CO.
If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.
Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the clutch assembly if the measurement is 26 mm (1.023 in) or less.

Fig 12: Measuring Distance Between Adjuster Ring 1 Long Hole And Lever 1 Spring
Courtesy of FORD MOTOR CO.
Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the measurement is 15 mm (0.59 in) or less.

Fig 13: Measuring Distance Between Adjuster Ring 2 And Cover
Courtesy of FORD MOTOR CO.
Apply a small amount of transmission fluid on the input shaft bearing surface.

Fig 14: Identifying Transmission Fluid Applying Areas On Input Shaft Bearing Surface
Courtesy of FORD MOTOR CO.
Apply a small amount of DPS6 Grease on both input shaft splines.

Fig 15: Identifying Grease Applying Areas On Input Shaft Splines
Courtesy of FORD MOTOR CO.
Verify the Z-washers are installed correctly.

Fig 16: Inspecting Z-Washers Installation Position
Courtesy of FORD MOTOR CO.

NOTE: Do not tilt the transmission until after Step 26 when the clutch locks are released. Failure to do so may cause the Z-washers to fall out of place, causing a noise issue or damage.
NOTE: Verify the clutch locks are locked prior to installation or the transaxle may not operate correctly and damage can occur. If the clutch locks are not locked go to step 2 within this procedure.

NOTE: Make sure the angled lifting leg is installed in the location shown in illustration.

Using the special tools, install the clutch in the transaxle.

Fig 17: Installing Clutch Into Transaxle Using Special Tools
Courtesy of FORD MOTOR CO.
Remove all the special tools.

Fig 18: Locating Special Tools Mounting Nuts
Courtesy of FORD MOTOR CO.
Install the special tools onto the transaxle case.

Fig 19: Installing Special Tools Onto Transaxle Case
Courtesy of FORD MOTOR CO.
NOTE: Do not overtighten the special tool or damage can occur.

Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft bearing and the snap ring groove is visible.

Fig 20: Installing Special Tools Onto Transaxle Case
Courtesy of FORD MOTOR CO.
NOTE: Make sure the hollow input shaft snap ring is fully seated.

Install the new hollow input shaft snap ring.

Fig 21: Locating Hollow Input Shaft Snap Ring
Courtesy of FORD MOTOR CO.
NOTE: Align the index marks on the clutch hub and clutch.

Install the clutch hub.

Fig 22: Removing/Installing Clutch Hub
Courtesy of FORD MOTOR CO.
Install the new clutch hub snap ring in the position shown in illustration.

Fig 23: Installing Clutch Hub Snap Ring
Courtesy of FORD MOTOR CO.
NOTE: Do not turn the special tool more than 12 turns or damage to the clutch actuator engagement lever can occur.

Using the special tool, release the clutch 1 locks and then the clutch 2 locks by slowly turning the special tool counterclockwise. An audible click will be heard when the clutch locks are released.

Fig 24: Releasing Clutch 1 And 2 Locks Using Special Tool
Courtesy of FORD MOTOR CO.
Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.

Fig 25: Identifying Lubricant Applying Areas On Clutch Motor Surfaces
Courtesy of FORD MOTOR CO.
Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown in illustration.

Fig 26: Identifying Lubricant Applying Areas On Clutch Actuator Lever Splines
Courtesy of FORD MOTOR CO.
Install the clutch motor 2 and the 4 clutch motor 2 bolts.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 27: Locating Clutch Motor 2 And Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the clutch motor 1 and the 4 clutch motor 1 bolts.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 28: Locating Clutch Motor 1 And Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: After installation of the transaxle be sure to perform the CLUTCH ADAPTIVE LEARNING procedure or transaxle damage can occur. For additional information, refer to TRANSMISSION ADAPTIVE LEARNING .

Install the transaxle in the vehicle. For additional information, refer to TRANSAXLE .