Ford Focus Service Manual: Direct Clutch
Special Tool(s)
|
Compressor, Spring Washer
307-209 |
|
Dial Indicator Gauge With Holding Fixture
100-002 (TOOL-4201-C) |
Material
Item |
Specification |
Motorcraft® MERCON® LV Automatic Transmission Fluid
XT-10-QLVC (US); CXT-10-LV12 (Canada) |
MERCON® LV |
Item |
Part Number |
Description |
1 |
7D483 |
Selective retaining ring |
2 |
7B066 |
Direct clutch pressure plate |
3 |
7B164 |
Friction plates |
4 |
7B442 |
Steel plates — forward clutch separator |
5 |
7H363 |
Snap ring |
6 |
7H359 |
Direct clutch balance piston |
7 |
7F235 |
Direct clutch return spring |
8 |
7A262 |
Direct clutch piston |
9 |
7H335 |
Bearing — direct clutch thrust |
10 |
7F283 |
Cylinder assembly — direct clutch |
Disassembly
- Remove the direct clutch pressure, friction and steel plates.
- Remove the selective retaining ring.
- Remove the plates.
- Using the Spring Washer Compressor, remove the snap ring.
- Remove the direct clutch balance piston.
- Remove the direct clutch return spring.
- NOTICE: If damage is found on the direct clutch piston seals, install
a new direct clutch piston.
Remove and inspect the direct clutch piston.
Assembly
- Soak the internal spline clutch plates in clean transmission fluid.
- Inspect the direct clutch piston bore surfaces for nicks or scratches. Install
a new direct clutch piston if necessary.
- Lubricate with clean transmission fluid and install the direct clutch piston.
- Install the direct clutch return spring.
- Install the direct clutch balance piston.
- Using the Spring Washer Compressor, install the snap ring.
- Install the direct clutch pressure, friction and steel plates.
- Install the plates.
- Install the selective retaining ring.
- Measure the clutch pack clearance.
- Install the direct clutch on the transaxle end cover.
- Install the Dial Indicator Gauge With Holding Fixture on the transaxle
end cover and position the Dial Indicator plunger on the pressure plate.
- Using a suitable tool, lift up on both sides of the clutch pack and
measure and record the clutch pack clearance on the Dial Indicator in 3
different areas. Average the measurements.
- Compare the direct clutch pack clearance to the specification (1.0-1.3 mm
[0.039-0.051 in]). If the clutch pack clearance is not within specification,
select and install the correct size retaining ring to obtain the specified clearance.
Part Number |
Thickness |
XS4Z-7D483-CA |
1.15-1.25 mm (0.045-0.049 in) |
XS4Z-7D483-CB |
1.35-1.45 mm (0.053-0.057 in) |
XS4Z-7D483-CC |
1.55-1.65 mm (0.061-0.064 in) |
XS4Z-7D483-CD |
1.75-1.85 mm (0.068-0.072 in) |
XS4Z-7D483-CE |
1.95-2.05 mm (0.076-0.080 in) |
XS4Z-7D483-CF |
2.15-2.25 mm (0.084-0.088 in) |
Material
Item
Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid
XT-10-QLVC (US); CXT-10-LV12 (Canada)
MERCON® LV
Motorcraft® Metal Surface ...
Item
Part Number
Description
1
7D483
Snap ring
2
7A019
Rear sun gear assembly
3
7C041
Thrust bearing assembly
4
...
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