Intermediate Clutch Assembly

Intermediate Clutch Assembly

Disassembly

NOTE: Clutch plate quantity is model dependant based on engine displacement:
- 4.6L engine (Explorer, Mountaineer, Sport Trac, F-150)
- Four friction plates
- Four steel plates

- 5.4L engine (Expedition, Navigator, F-150)
- Five friction plates
- Five steel plates

1. Remove the T6 thrust bearing.

2. Remove the intermediate clutch plate snap ring.

3. Remove the intermediate clutch plates.

4. Using the Clutch Spring Compressor 307-525, remove and discard the intermediate clutch return spring retainer.

5. Remove the intermediate clutch return spring top plate.

6. Remove the intermediate clutch return spring.

7. Applying a slight amount of air to the port, 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 Clutch Spring Compressor 307-525, install a new intermediate clutch return spring retainer.

6. NOTE: Friction and steel plate quantity will vary based on engine displacement. For additional information, refer to the Clutch Plate Quantity Chart in the Specifications.

Soak the new intermediate clutch plates in clean automatic transmission fluid.

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

8. Install the intermediate clutch plate snap ring.

9. NOTE: All intermediate clutch plates, friction and steel are of a wave-type design.

Install the intermediate clutch assembly into the Clutch End Play Gauge 307-555 and install the Dial Indicator Gauge with Holding Fixture 100-002 and position the plunger so it fits into the opening of the snap ring.

10. With the Dial Indicator Gauge 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.

11. Rotate the intermediate clutch assembly 180 degrees from the opening of the snap ring, take a second reading and record this reading as reading B.

12. NOTE: If the final measurement is not within specification, install a new snap ring until the correct specification is achieved.
- 5.4L engine - 0.7-1.1 mm (0.027-0.043 in).
- 4.6L engine - 0.7-1.1 mm (0.027-0.043 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.

13. Install the T6 thrust bearing.