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Home >> Ford >> 2010 >> Mustang Base, 2D Convertible, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - Automatic Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> Forward Clutch >> Assembly
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Forward Clutch: Assembly

  1. Inspect the clutch components for damage or wear. Install new components as necessary.
    • Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
    • Inspect the clutch plates for damage.
    • Inspect the clutch springs.
    • Inspect the needle bearing and seal rings for damage.
    • Check clutch hub thrust surfaces for damage.
    • Check clutch plates for flatness and fit on the clutch hub serrations.
    2. NOTE: If the seals on the forward clutch piston show any signs of damage, a new forward clutch piston will need to be installed.
    Fig 1: Locating Forward Clutch Piston And Seals
    G06395934Courtesy of FORD MOTOR CO.
  2. Inspect the forward clutch piston and seals.
  3. Inspect the forward clutch drum assembly.
    1. Inspect the forward clutch cylinder surfaces for scores or burrs.
    2. Inspect the forward clutch piston for scores or burrs.
    3. Verify the check ball is free to move in the piston.
      Fig 2: Inspecting Forward Clutch Cylinder Surfaces For Scores Or Burrs
      G06395935Courtesy of FORD MOTOR CO.
    4. NOTE: The Forward Clutch Seal Gauge must be installed on the forward clutch piston for a couple of minutes prior to installing it into the forward clutch cylinder.
    Fig 3: Identifying Special Tool
    G06395936Courtesy of FORD MOTOR CO.
  4. Install the Forward Clutch Seal Gauge on the forward clutch piston.
    5. NOTE: Care must be taken to prevent damage to the seals.
    NOTE: Lubricate the forward clutch piston inner and outer seal with automatic transmission fluid.
    Fig 4: Installing Forward Clutch Piston Assembly Into Forward Clutch Cylinder
    G06395937Courtesy of FORD MOTOR CO.
  5. Using the Piston Seal Protector, install the forward clutch piston assembly into the forward clutch cylinder.
  6. Install the forward clutch piston spring assembly.
    Fig 5: Locating Forward Clutch Piston Spring Assembly
    G06395932Courtesy of FORD MOTOR CO.
    7. NOTE: Do not fully depress the Clutch Spring Compressor or damage to the spring retainer may occur.
    Fig 6: Installing Forward Clutch Piston Spring Retaining Ring
    G06395931Courtesy of FORD MOTOR CO.
  7. Using the Clutch Spring Compressor, install the forward clutch piston spring retaining ring.
    8. NOTE: The forward clutch friction plates are directional and must be installed with grooves pointing counterclockwise, otherwise transmission damage can occur.
    NOTE: If new plates are used, they should be soaked in automatic transmission fluid before assembly, otherwise transmission damage can occur.
    Fig 7: Installing Direct Clutch Disc Pack
    G06395940Courtesy of FORD MOTOR CO.
  8. If reusing plates, grooves must be installed counterclockwise. Install the forward clutch disc pack.
  9. Install the steel clutch plates and friction clutch plates in alternating order starting with a steel clutch plate.
    Fig 8: Locating Forward Clutch Disc Pack
    G06395930Courtesy of FORD MOTOR CO.
    10. NOTE: The retaining ring is a select fit.
  10. Install the original selective retaining ring.
    1. Install the forward clutch pressure plate.
    2. Install the original selective retaining ring.
      Fig 9: Identifying Original Selective Retaining Ring And Forward Clutch Pressure Plate
      G06395942Courtesy of FORD MOTOR CO.
    11. WARNING: When using compressed air, never let air pressure exceed 138 kPa (20 psi) and always wear safety glasses. Compressed air may cause foreign material or parts to become airborne. Failure to follow this instruction may result in serious personal injury.
  11. Air check the forward clutch piston.
    1. Place the forward clutch cylinder with the forward clutch piston facing down.
    2. Install the transmission center support on the forward clutch cylinder.
    3. Apply air pressure to the left port of the center support.
      Fig 10: Applying Air Pressure To Left Port Of Center Support
      G06395943Courtesy of FORD MOTOR CO.
  12. Check the forward clutch disc pack free play.
    1. Press down on the forward clutch disc pack.
    2. Using a feeler gauge, check the gap between the forward clutch retaining ring and the forward clutch pressure plate.
      • If the clearance is not within specifications, install the correct size retaining ring.
        THICKNESS SPECIFICATION

        Part Number Thickness Diameter
        mm Inch mm Inch
        XW4Z-7D483-AB 1.73 0.068 141.45 5.568
        XW4Z-7D483-AC 2.08 0.081 141.45 5.568
        XW4Z-7D483-AD 2.44 0.096 141.45 5.568
        Fig 11: Checking Gap Between Forward Clutch Retaining Ring And Forward Clutch Pressure Plate
        G06395944Courtesy of FORD MOTOR CO.
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