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Forward-Coast-Direct Clutch Cylinder and Reverse Clutch Drum - Assembly > < Forward-Coast-Direct Clutch Cylinder and Reverse Clutch Drum - Disassembly - Vehicles Built From: 12-2003

Maverick 2005 (08.2004-)

Automatic Transmission/Transaxle - Forward/Coast/Direct Clutches Maverick 2005 (08/2004-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Dial Indicator Gauge with Holding Fixture

100-D002 (D78P-4201-B)

Protector, Piston Seal

307-282 (T94P-77000-D3)

Compressor, Clutch Spring

307-015 (T65L-77515-A)

Remover, O-Ring Seal

100-010 (T71P-19703-C)
Materials
Name
Specification
MERCON(R) V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)
MERCON(R) V

 
Item
Part Number
Description
1
7D483
Retaining ring — direct clutch pressure plate
2
7B477
Pressure plate — direct clutch
3
7B164
Clutch plates — direct clutch internal spline (friction)
4
7B442
Clutch plates — direct clutch external spline (steel)
5
7C122
Retaining ring — direct clutch spring
6
7F235
Return spring — direct clutch
7
7F225
Piston inner lip seal — direct clutch
8
7A262
Piston assembly — direct clutch
9
7A548
Piston outer lip seal — direct clutch
10
7G120
Cylinder assembly — forward/coast/direct clutch
11
7A548
Piston inner lip seal — forward clutch
12
7A262
Piston assembly — forward clutch
13
7A548
Piston outer lip seal — forward clutch
14
7A262
Piston and seal assembly — coast clutch
15
7G299
Return spring — forward/coast clutch
16
7N169
Retaining ring — forward clutch spring
17
—
Clearance for fingers on the forward clutch piston
18
7B442
Clutch plates — coast clutch external spline (steel)
19
7B164
Clutch plates — coast clutch internal spline (friction)
20
7B066
Pressure plate — coast clutch
21
74159
Wave spring — forward clutch
22
7B164
Internal spline clutch plates — forward clutch (friction)
23
7B442
External spline clutch plates — forward clutch (steel)
24
7B066
Pressure plate — forward clutch
25
7D483
Retaining ring — forward clutch pressure plate

Disassembly
  1. Remove the direct clutch pressure plate retaining ring.

  1. Disassemble the direct clutch pack.
    1. Remove the direct clutch pressure plate.
    1. Remove the direct clutch steel plates.
    1. Remove the direct clutch friction plates.

  1. WARNING:
    WARNING:Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Do not compress the direct clutch return springs completely.
    Remove the direct clutch spring retaining ring.
    1. Using the special tool, compress the direct clutch return springs.
    1. Remove the direct clutch return spring retaining ring.

  1. Remove the direct clutch return spring assembly.

  1. Remove the direct clutch piston assembly.

  1. Remove and discard the direct clutch piston outer lip seal.

  1. Remove and discard the direct clutch piston inner lip seal from the forward/coast/direct clutch cylinder assembly.

  1. Remove the forward clutch pressure plate retaining ring.

  1. Remove the forward and coast clutch plates.
    1. Forward clutch pressure plate
    1. Forward clutch external spline clutch plates (steel)
    1. Coast clutch internal spline clutch plates (friction)
    1. Coast clutch external spline clutch plates (steel)
    1. Coast clutch pressure plate
    1. Forward clutch wave spring
    1. Forward clutch internal spline clutch plates (friction)

  1. WARNING:
    WARNING:Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
    CAUTION:
    CAUTION:Do not compress the return springs completely.
    Remove the forward/coast clutch return spring retaining ring.
    1. Using the special tool, compress the return spring.
    1. Remove the retaining ring.

  1. Remove the forward/coast clutch return spring assembly.

  1. Remove the forward and coast clutch pistons.

  1. Using the special tool, remove and discard the forward clutch piston inner seal from the forward/coast/direct clutch cylinder assembly.

  1. Remove and discard the forward clutch piston outer lip seal.

  1. Separate the coast clutch piston assembly from the forward clutch piston assembly.
  1. WARNING:
    WARNING:Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury.
    NOTE:
    NOTE:Do not clean the clutch plates in a vapor degreaser or in any other type of detergent solution.
    Clean all parts thoroughly in a clean automatic transmission fluid and blow dry with moisture-free regulated compressed air.
    • Clean the steel clutch plates with a lint-free cloth.
    • Soak the new clutch plates in the specified transmission fluid before assembly.
  1. Inspect the parts for damage, cracks or wear.
    • Spline teeth
    • Clutch plates
    • Seals
    • Bushing
    • Check balls in pistons
    • Piston bore
    • Passages and lubrication holes in the forward/coast/direct clutch cylinder
    • Center hub weld
    • Large snap ring grooves

Assembly

  1. Soak the internal spline clutch plates in clean automatic transmission fluid.

  1. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.

  1. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.

  1. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.

  1. Mark the center of 2 adjacent legs on the top of the cylinder.

  1. Find the center between the marks (45 degrees from either leg) and mark the cylinder.

  1. Install the coast clutch piston assembly onto the special tool.

  1. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.

  1. Install the forward/coast clutch return spring assembly.

  1. WARNING:
    WARNING:Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
    Install the forward/coast clutch return spring retaining ring.
    1. Using the special tool, compress the return spring.
    1. Install the forward/coast clutch retaining ring.
    • Orient the gap between the piston legs.

  1. Install the forward and coast clutch plates in the sequence shown.
    1. Coast clutch external spline clutch plates (steel)
    1. Coast clutch internal spline clutch plates (friction)
    1. Coast clutch pressure plate
    1. Forward clutch wave spring
    1. Forward clutch internal spline clutch plates (friction)
    1. Forward clutch external spline clutch plates (steel)
    1. Forward clutch pressure plate

  1. Install the forward clutch pressure plate retaining ring.
    • Center the select fit retaining ring on the 45 degree mark between the 2 adjacent legs.

  1. Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring.
    • Take a second measurement on the opposite side.
    • Average the 2 measurements to get the clearance.
    • If the clearance is not within specification, select and install the correct thickness retaining ring to obtain the standard clearance.
    • Retaining ring sizes:

        • 1. 1.43-1.53 mm (0.056-0.060 in).

        2. 1.59-1.69 mm (0.062-0.066 in).

        3. 1.75-1.85 mm (0.069-0.073 in).

        4. 1.92-2.02 mm (0.075-0.079 in).

  1. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.

  1. Install the direct clutch piston outer seal on the direct clutch piston assembly.

  1. NOTE:
    NOTE:Position the lip seal facing down.
    Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.

  1. Install the direct clutch return spring assembly.

  1. WARNING:
    WARNING:Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
    CAUTION:
    CAUTION:Do not compress the direct clutch return springs completely.
    Install the direct clutch return spring retaining ring.
    1. Using the special tool, compress the direct clutch return springs.
    1. Install the direct clutch return spring retaining ring.

  1. NOTE:
    NOTE:Quantity of plates are model dependent.
    Install the direct clutch plates.
    1. Install the direct clutch external spline (steel) clutch plates.
    1. Install the direct clutch internal spline (friction) clutch plates.
    1. Install the direct clutch pressure plate.

  1. Install the direct clutch pressure plate retaining ring.

  1. Measure the direct clutch clearance as follows:
    • Install the special tool.
    • Zero the dial on the direct clutch pressure plate.
    • Pull the direct clutch pressure plate upward, and record the reading.

  1. Make a second measurement on the opposite side. Average the 2 measurements to get the clearance. If the clearance is not within the specification, select and install, using the special tool, the correct thickness direct clutch pressure plate retainer snap ring to obtain the standard clearance.
    • Retaining ring sizes:

        • 1. 1.28-1.38 mm (0.050-0.054 in).

        2. 1.39-1.49 mm (0.054-0.058 in).

        3. 1.52-1.62 mm (0.059-0.063 in).

        4. 1.65-1.75 mm (0.064-0.069 in).

Forward-Coast-Direct Clutch Cylinder and Reverse Clutch Drum - Assembly > < Forward-Coast-Direct Clutch Cylinder and Reverse Clutch Drum - Disassembly - Vehicles Built From: 12-2003