Direct Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2007 Ford Expedition EL and 2007 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.

Remove and discard the 2 scarf cut seals and the roller bearing.

Fig 1: Locating Scarf Cut Seals And Roller Bearing

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Remove the thrust bearing (T5).

Fig 2: Locating Thrust Bearing (T5)

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Remove the direct clutch snap ring.

Fig 3: Locating Direct Clutch Snap Ring

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Remove the direct clutch steel and friction plates.

Fig 4: Locating Direct Clutch Steel And Friction Plates

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Install the special tools onto the direct clutch assembly.

Fig 5: Identifying Special Tools & Direct Clutch Assembly

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Using the special tool, remove the direct clutch return spring retainer.

Fig 6: Identifying Special Tool & Direct Clutch Return Spring Retainer

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Remove the special tool.

Fig 7: Identifying Special Tool

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Remove the direct clutch return spring washer.

Fig 8: Locating Direct Clutch Return Spring Washer

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Remove the direct clutch return spring.

Fig 9: Identifying Direct Clutch Return Spring

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Slightly press down on the balance piston and remove and discard the snap ring.

Fig 10: Locating Snap Ring

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Remove the baffle plate from the direct clutch piston.

Fig 11: Locating Baffle Plate

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Remove the direct clutch piston.

Fig 12: Locating Direct Clutch Piston

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Remove and discard the outer O-ring seal from the balance piston.

Fig 13: Locating Outer O-Ring Seal

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Remove and discard the outer and inner O-ring seal from the apply piston.

Fig 14: Locating Inner And Outer O-Ring Seal

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Inspect the direct clutch drum for damage. If damage is indicated, install a new direct clutch drum.