Automatic Transaxle / Transmission DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES output shaft and direct clutch cylinder seal 307-015 (T65L-77515-A) Sizer, seal 307-516-4 Protector, Piston Seal 307-080 (T80L-77234-A) Material Item Protector, Transmission Direct Clutch Outer Fluid Seal 307-422 MERCON(r) V Teflon seal
Automatic Transaxle / Transmission DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES output shaft and direct clutch cylinder seal 307-015 (T65L-77515-A) Sizer, seal 307-516-4 Protector, Piston Seal 307-080 (T80L-77234-A) Material Item Protector, Transmission Direct Clutch Outer Fluid Seal 307-422 MERCON(r) V Teflon seal
Automatic Transaxle / Transmission DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES output shaft and direct clutch cylinder seal 307-015 (T65L-77515-A) Sizer, seal 307-516-4 Protector, Piston Seal 307-080 (T80L-77234-A) Material Item Protector, Transmission Direct Clutch Outer Fluid Seal 307-422 MERCON(r) V Teflon seal
Automatic Transaxle / Transmission DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES output shaft and direct clutch cylinder seal 307-015 (T65L-77515-A) Sizer, seal 307-516-4 Protector, Piston Seal 307-080 (T80L-77234-A) Material Item Protector, Transmission Direct Clutch Outer Fluid Seal 307-422 MERCON(r) V Teflon seal
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307-01-1
Automatic Transaxle/Transmission
307-01-1
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft and Direct Clutch Cylinder Special Tool(s) Compressor, Clutch Spring 307-015 (T65L-77515-A) Sizer, Seal 307-516-4 Special Tool(s) Assembly Pusher 307-516-3
Protector, Piston Seal 307-080 (T80L-77234-A)
Material Item Protector, Transmission Direct Clutch Outer Fluid Seal 307-422 MERCON V Automatic Transmission Fluid XT-5-QM Specification MERCON V
Teflon Seal Installer 307-516 (kit consists of 307-516-1, 307-516-2, 307-516-3 and 307-516-4)
Protector Pilot, Seal 307-516-1
Protector, Seal 307-516-2
(Continued)
Copyright 2003, Ford Motor Company
Last updated: 5/26/2005
2004 Mustang, 11/2003
307-01-2
Automatic Transaxle/Transmission
307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Output Shaft and Hub Disassembled View
Item 1 2 3 4
Part Number 7F274 7F240 7060 7F273
Description Output shaft to direct clutch cylinder seal (2 reqd) Direct clutch outer bearing and race assembly No. 8 Output shaft Output shaft-to-case seal (3 reqd)
Item 5 6 7 8 9
Part Number 87054-S94 7A233 7D164 97713-S 7C122
Description O-ring seal Output shaft ring gear assembly Output shaft hub Retaining snap ring Snap ring
(Continued)
Direct Clutch Disassembled View
2004 Mustang, 11/2003
307-01-3
Automatic Transaxle/Transmission
307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number 7F236 7F243 7D483 7F237 7B066 7B442 7B164 388104-S2 7F235 7A262 7C099 7A548 7F283 Description Direct clutch hub No. 7 direct clutch bearing Direct clutch pressure plate retaining ring Direct clutch inner bearing support Direct clutch pressure plate Direct clutch external spline plates (steel) Direct clutch internal spline plates (friction) Retaining ring Direct clutch retainer and spring assembly Direct clutch piston Direct clutch piston inner seal Direct clutch piston outer seal Direct clutch cylinder
Disassembly 1. NOTE: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear during the assembly procedure. Remove the ring gear snap ring.
2.
Separate the ring gear and output shaft.
2004 Mustang, 11/2003
307-01-4
Automatic Transaxle/Transmission
307-01-4
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
3. Remove the three output shaft seal rings.
7. 4. Remove the output shaft hub snap ring and the output shaft hub. 8.
Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Install a new clutch cylinder if badly scored or damaged. Check the fluid passages in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install new if necessary. Inspect the check balls for freedom of movement and correct seating. Check clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
9.
5.
Remove the two direct clutch seal rings.
10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred. 11. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat. 12. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.
6.
Remove the No. 7 direct clutch inner bearing support. 1 2 Remove the direct clutch hub. Remove the No. 7 direct clutch inner bearing support.
2004 Mustang, 11/2003
307-01-5
Automatic Transaxle/Transmission
307-01-5
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
13. Remove the direct clutch pack. 1 2 Remove the selective retaining ring. Remove the direct clutch pack. 15. WARNING: Wear safety glasses when using compressed air. NOTE: If necessary, use regulated compressed air 207 kPa (30 psi) maximum pressure to remove the clutch piston. Remove the support and spring assembly and piston.
16. Remove the inner piston seal.
14. Using the special tool, compress the piston return spring and remove the snap ring.
17. Remove the outer piston seal.
2004 Mustang, 11/2003
307-01-6
Automatic Transaxle/Transmission
307-01-6
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Assembly 1. NOTE: Lubricate the direct clutch piston inner seal and seal protector with petroleum jelly. Using the special tool, install the inner piston seal. Install the seal with sealing lip facing down. 3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly. Using the special tool, install the direct clutch piston.
4. 2. Install the clutch piston outer seal so that when the piston is installed, the sealing lip points toward the bottom of the cylinder. 5.
Install the piston return spring and retainer assembly. Using the special tool, compress the piston return spring and install the retaining ring.
2004 Mustang, 11/2003
307-01-7
Automatic Transaxle/Transmission
307-01-7
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
6. NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid. Install the clutch pack retaining ring. 1 Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate. Install the clutch pack retaining ring.
8.
Install the direct clutch hub. 1 2 Install the No. 7 direct clutch inner bearing support. Install the direct clutch hub.
NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings. 9. 7. Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate. If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance. Using the special tool install the first direct clutch seal ring.
Selective Retaining Ring Specification 1.270-1.372 mm (0.050-0.054 inch) 1.625-1.727 mm (0.064-0.068 inch) 1.981-2.083 mm (0.078-0.082 inch) 2.337-2.438 mm (0.092-0.096 inch)
2004 Mustang, 11/2003
307-01-8
Automatic Transaxle/Transmission
307-01-8
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
10. Using the special tool, install the second direct clutch seal ring. 13. Install the three output shaft seal rings.
11. After both new seals have been installed, use the special tool to size the seals.
14. Install the No. 8 needle bearing on the direct clutch cylinder.
12. Install the output shaft hub. Position the output shaft hub. Install the retaining ring.
15. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub. Assemble the direct clutch on the output shaft.
2004 Mustang, 11/2003
307-01-9
Automatic Transaxle/Transmission
307-01-9
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
16. CAUTION: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear. Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.
