Intermediate Clutch Assembly

Intermediate Clutch Assembly

Special Tool(s):

Material:

Intermediate Clutch Assembly:

Disassembly
1. Remove the bearing race.





2. Remove the intermediate clutch plate snap ring.





3. Remove the intermediate clutch plates, friction and steel, from the intermediate clutch cylinder.





4. Using the special tool, remove the intermediate clutch return spring retainer.





5. Remove the intermediate clutch return spring top plate.





6. Remove the intermediate clutch return spring.





7. Remove the intermediate clutch piston.





8. Remove and discard the inner and outer intermediate clutch piston O-ring seals.





Assembly
1. Install new inner and outer intermediate clutch piston O-ring seals.





2. Lightly coat the O-ring seals in clean automatic transmission fluid and install the intermediate clutch piston.





3. Install the intermediate clutch return spring.





4. Install the intermediate clutch return spring top plate.





5. Using the special tool, install the intermediate clutch return spring retainer.





6. NOTE: Before assembly, soak the new clutch plates in clean automatic transmission fluid.

Install the new intermediate clutch plates, starting with the wave spring then a steel plate and alternating between and fiber and steel plates, and ending with the pressure plate.
7. Install the intermediate clutch plate snap ring.





8. Install the intermediate clutch drum into the special tool.





9. With the dial indicator set at zero, lift up on the steel pressure plate so it is against the select fit snap ring. Record this reading as reading A.
10. Rotate the direct clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.








11. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.

^ 5.4L engine 0.71-1.10 mm (0.028-0.043 in).
If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
12. Install the bearing race.