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Home >> Ford >> 2002 >> Crown Victoria Base, 4.6 9 >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Disassembly & Assembly Of Subassemblies >> Output Shaft & Direct Clutch Cylinder >> Disassembly

Output Shaft & Direct Clutch Cylinder: Disassembly

    NOTE: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear during the assembly procedure.
    Fig 1: Identifying Ring Gear Snap Ring
    G01940522Courtesy of FORD MOTOR CO.
  1. Remove the ring gear snap ring.
  2. Separate the ring gear and output shaft.
    Fig 2: Identifying Output Shaft
    G01940523Courtesy of FORD MOTOR CO.
  3. Remove the three output shaft seal rings.
    Fig 3: Identifying Output Shaft Seal Rings
    G01940524Courtesy of FORD MOTOR CO.
  4. Remove the output shaft hub snap ring and the output shaft hub.
    Fig 4: Identifying Output Shaft Hub Snap Ring
    G01940525Courtesy of FORD MOTOR CO.
  5. Remove the two direct clutch seal rings.
    Fig 5: Identifying Direct Clutch Seal Rings
    G01940526Courtesy of FORD MOTOR CO.
  6. Remove the No. 7 direct clutch inner bearing support.
    1. Remove the direct clutch hub.
    2. Remove the No. 7 direct clutch inner bearing support.
    Fig 6: Identifying Direct Clutch Hub & No. 7 Direct Clutch Inner Bearing Support
    G01940527Courtesy of FORD MOTOR CO.
  7. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Install a new clutch cylinder if badly scored or damaged.
  8. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install new if necessary. Inspect the check balls for freedom of movement and correct seating.
  9. Check the clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
  10. Inspect the composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
  11. Check the clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
  12. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.
  13. Remove the direct clutch pack.
    1. Remove the selective retaining ring.
    2. Remove the direct clutch pack.
    Fig 7: Identifying Selective Retaining Ring & Direct Clutch Pack
    G01940528Courtesy of FORD MOTOR CO.
  14. Using the special tool, compress the piston return spring and remove the snap ring.
    Fig 8: Identifying Snap Ring
    G01940529Courtesy of FORD MOTOR CO.
    15. WARNING: Wear safety glasses when using compressed air.
    NOTE: If necessary, use regulated compressed air (207 kPa max pressure) to remove the clutch piston.
    Fig 9: Identifying Support, Spring Assembly & Piston
    G01940530Courtesy of FORD MOTOR CO.
  15. Remove the support and spring assembly and piston.
  16. Remove the inner piston seal.
    Fig 10: Identifying Inner Piston Seal
    G01940531Courtesy of FORD MOTOR CO.
  17. Remove the outer piston seal.
    Fig 11: Identifying Outer Piston Seal
    G01940532Courtesy of FORD MOTOR CO.
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