Thunderbird V8-302 5.0L HO (1992)
Clutch: Service and Repair
Forward Clutch
DISASSEMBLY
Exploded View Of Forward Clutch
1. Remove clutch hub and No. 3 needle bearing, if not previously removed.
2. Remove clutch pack selective retaining ring.
3. Remove clutch pack.
4. Using suitable tools, compress piston return spring and remove retaining ring and spring retainer.
5. Note position and direction of lip seals, then remove clutch piston and ensure check balls in piston are free.
ASSEMBLY
1. Install new seals on clutch piston, noting direction of sealing lips.
2. Install clutch piston as follows:
a. Coat piston seals and clutch drum sealing area with petroleum jelly.
b. Install forward clutch inner lip seal protector T8OL-77140-A or equivalent over clutch cylinder hub.
c. Install piston in forward clutch outer lip seal protector T68P-7D158-A or equivalent.
d. Position seal protector and piston in clutch drum and push piston to bottom of drum using even thumb pressure.
3. Using suitable tools, install piston return spring, spring retainer, and the retaining ring.
4. Install clutch pack, wave plate first.
5. Install clutch pack retaining ring and check clearance between ring and pressure plate, holding pressure plate downward while checking clearance.
Forward Clutch Clearance Chart
6. If clearance is not within specifications, install correct replacement snap ring and recheck clearance. Snap rings are available in inch thicknesses of
0.060-0.064, 0.074-0.078, 0.088-0.092, and 0.102-0.106.
7. Check clutch for proper operation using air pressure. Clutch should be heard and felt to apply smoothly without leakage.
