E 350 Van V8-7.3L DSL Turbo VIN F (1995)
Clutch: Service and Repair
Intermediate Clutch
Intermediate Brake Drum
DISASSEMBLE
1. Remove one-way clutch outer race, then the one-way clutch assembly with end caps.
2. Remove large brass thrust washer No. 7G401 from rear face of cylinder.
3. Remove small brass thrust washer No. 7D428 from front face of cylinder.
4. Using screwdriver, remove snap ring, then the pressure plate and clutch pack. Tag parts for assembly reference.
Return Spring Snap Ring Replacement
5. Remove return spring snap ring as shown in the Return Spring Snap Ring Replacement image.
6. Remove return spring assembly and piston from intermediate brake drum.
7. Remove inner and outer seals from intermediate brake drum.
ASSEMBLE
NOTE: Soak all friction plates in clean transmission fluid for fifteen minutes.
1. Install inner and outer seal into drum with seal groove facing down.
2. Inspect piston check ball for freedom of movement and clean as necessary.
3. Install piston and return spring assembly in drum.
4. Install return spring snap ring as shown in the Return Spring Snap Ring Replacement image. Ensure protrusions on spring retainer are properly
engaged with lugs on clutch piston.
5. Install four plate clutch pack starting with steel plate.
6. Install pressure plate.
7. Install selective snap ring. Using feeler gauge, check stack-up. Clearance should not exceed 0.060-0.045 inch.
8. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes,
0.065-0.069 inch, 0.074-0.078 inch and 0.083-0.087 inch.
9. Install small brass thrust washer No. 7D428 from front face of cylinder.
10. Install large brass thrust washer No. 7G401 from rear face of cylinder.
11. Install one-way clutch end cap, one-way clutch assembly, outer race, and outer race end cap, noting the following:
a. Lip is up on one-way clutch.
b. Outer race must turn counterclockwise.
c. Outer race end cap is installed over inner race.
Intermediate Overdrive Cylinder
REMOVAL
