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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 >> Assembly

Output Shaft & Direct Clutch Cylinder: Assembly

    NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly.
    Fig 1: Identifying Seal With Sealing Lip Facing Down
    G01940533Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the inner piston seal.
    • Install the seal with sealing lip facing down.
  2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder.
    Fig 2: Identifying Clutch Piston Outer Seal
    G01940534Courtesy of FORD MOTOR CO.
    3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.
    Fig 3: Identifying Direct Clutch Piston
    G01940535Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the direct clutch piston.
  4. Install the piston return spring and retainer assembly.
  5. Using the special tool, compress the piston return spring and install the retaining ring.
    Fig 4: Identifying Retaining Ring
    G01940536Courtesy of FORD MOTOR CO.
    6. NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid for 15 minutes.
    Fig 5: Identifying Clutch Pack Retaining Ring
    G01940537Courtesy of FORD MOTOR CO.
  6. Install the clutch pack retaining ring.
    1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
    2. Install the clutch pack retaining ring.
  7. Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate.
    • If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.
    Fig 6: Identifying Selective Retaining Ring Specifications
    G01940538Courtesy of FORD MOTOR CO.
    Fig 7: Checking Clearance Between Clutch Pack Selective Retaining Ring & Pressure Plate
    G01940539Courtesy of FORD MOTOR CO.
  8. Install the direct clutch hub.
    1. Install the No. 7 direct clutch inner bearing support.
    2. Install the direct clutch hub.
    Fig 8: Identifying No. 7 Direct Clutch Inner Bearing Support & Direct Clutch Hub
    G01940540Courtesy of FORD MOTOR CO.
    NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings.
    9. CAUTION: Make sure the seals are lapped correctly. Internal damage may occur.
    Fig 9: Identifying Direct Clutch Seal Rings
    G01940541Courtesy of FORD MOTOR CO.
  9. Install the two direct clutch seal rings.
  10. Install the output shaft hub.
    • Position the output shaft hub.
    • Install the retaining ring.
    Fig 10: Installing Output Shaft Hub
    G01940542Courtesy of FORD MOTOR CO.
  11. Install the three output shaft seal rings.
    Fig 11: Identifying Output Shaft Seal Rings
    G01940543Courtesy of FORD MOTOR CO.
  12. Install the No. 8 needle bearing on the direct clutch cylinder.
    Fig 12: Identifying No. 8 Needle Bearing
    G01940544Courtesy of FORD MOTOR CO.
    13. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.
    Fig 13: Installing Direct Clutch On Output Shaft
    G01940545Courtesy of FORD MOTOR CO.
  13. Assemble the direct clutch on the output shaft.
    14. CAUTION: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear.
    Fig 14: Identifying Ring Gear & Output Shaft
    G01940546Courtesy of FORD MOTOR CO.
  14. Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.
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