Caution: See TSB 06-14-4

Low/Reverse Clutch Piston Assembly -Clutch

1. NOTE: Prior to disassembly, check the low/reverse clutch operation.

To check the low/reverse clutch operation, apply compressed air through the fluid passage.

• Apply a maximum air pressure of 390 kPa (57 psi)

2. NOTE: Prior to disassembly, check the low/reverse clutch clearance. Take several measurements and calculate the average value.

Use a feeler gauge to measure the clearance between the low/reverse clutch pressure plate and the low/reverse clutch pressure plate snap ring.

• If the clearance is not as specified, repair as necessary.

3. Remove the low/reverse clutch pressure plate snap ring.

4. Remove the (A) low/reverse clutch pressure plate and the (B) low/reverse clutch disc pack.

5. Use Return Spring Compressor to remove the low/reverse clutch piston spring snap ring.

1. Install Return Spring Compressor and compress the low/reverse clutch support and spring. Compress the low/reverse clutch support and spring only enough to remove the snap ring.
2. Remove the low/reverse clutch piston spring snap ring.

6. Remove the low/reverse clutch support and spring.

7. Remove the low/reverse clutch piston.

• Remove the low/reverse clutch piston by applying compressed air through the fluid passage. Apply a maximum air pressure of 390 kPa (57 psi) .

8. Remove the low/reverse clutch piston outer seal and the low/reverse clutch piston inner seal, and discard.

Assembly

CAUTION: Composition clutch plates and synthetic seals should not be cleaned in a vapor degreaser or with any type of detergent cleaner. To clean these parts, wipe them off with a lint free cloth. New clutch plates should be soaked in Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON for two hours before being assembled. MERCON (R) Automatic Transmission Fluid is being replaced by MERCON (R) V as a service fluid, as per TSB 06-14-4.

NOTE: Clutch clearances are adjusted by the selection of snap ring thickness. If the clearance is not within specification, adjust as necessary.

1. Clean the components with a suitable solvent and use compressed air to dry all parts and clean the fluid passages. Perform the following before assembly:

• Inspect the transmission case for damage or wear.
• Inspect all clutches for damage or wear.
• Check the low/reverse clutch piston and transmission case seal area for burrs or damage.

2. NOTE: Measure the facing thickness in three places and calculate the average value.

Measure the low/reverse plate facing thickness.

• If not within the specification, replace the friction plates.

3. NOTE: Do not compress the springs when measuring with vernier calipers.

Measure the free length of each spring of the low/reverse support and spring.

• The free length should be 14.3 mm (0.563 inch) . If not within the specification, replace the low/reverse clutch support and spring.

4. Apply Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the inner and outer faces of the new low/reverse clutch piston outer seal and the low/reverse clutch piston inner seal. Install the inner and outer seal on the low/reverse clutch piston.

5. Install the low/reverse clutch piston into the transmission case.

• Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the transmission case.

6. Seat the low/reverse clutch piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.

7. Install the low/reverse clutch support and spring.

8. Use Return Spring Compressor to install the low/reverse clutch piston spring snap ring.

1. Install Return Spring Compressor and compress the low/reverse clutch support and spring. Compress the low/reverse clutch support and spring only enough to install the snap ring.
2. Install the low/reverse clutch piston spring snap ring.

9. Install the (A) low/reverse clutch pressure plate and the (B) low/reverse clutch disc pack.

• The installation order is friction-steel-friction-steel-friction-steel.

10. Install the low/reverse clutch pressure plate snap ring.

11. NOTE: Take several measurements and calculate the average value.

With the low/reverse clutch assembled, check the low/reverse clutch disc pack clearance.

• Use a feeler gauge to measure between the low/reverse clutch pressure plate and the low/reverse clutch pressure plate snap ring. If the clearance is not within the specification, adjust it by selecting the proper snap ring.

12. To check the low/reverse clutch operation, apply compressed air through the fluid passage.

• Apply a maximum air pressure of 390 kPa (57 psi) .
• The clutch should make a solid apply sound, with no whistle or sign of leaks.

13. NOTE: Make certain the selected snap ring is identified for later assembly.

Removal of the low/reverse clutch pressure plate snap ring, the low/reverse clutch pressure plate, and the low/reverse clutch disc pack is required for transmission reassembly.