SECTION 307-01: Automatic Transaxle/Transmission — 6R80
2014 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Procedure revision date: 01/07/2013

Direct Clutch Assembly


Special Tool(s)
Compressor, Clutch Spring
307-015 (T65L-77515-A)
Compressor, Clutch Spring
307-552
Dial Indicator Gauge with Holding Fixture
100-002 (TOOL-4201-C) or equivalent
End Play Gauge, Clutch
307-555

Material
Item Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid
XT-10-QLVC (US); CXT-10-LV12 (Canada) 		MERCON® LV

Direct Clutch Assembly

Item Part Number Description
1 7D483 Direct clutch pressure plate retaining ring
2 7B066 Direct clutch pressure plate (thickness model dependant)
3 7B164 Direct clutch internal splined friction plates (quantity model dependant)
4 7B442 Direct clutch external splined steel plates (quantity model dependant)
5 — Direct clutch cushion plate (wave spring)
6 7C096 Bearing (T5)
7 7A577 Piston retaining ring
8 7A262 Direct clutch balance piston
9 7A548 Direct clutch balance piston seal
10 7B488 Return spring
11 7A262 Direct clutch apply piston
12 7A548 Direct clutch apply piston outer seal
13 7C099 Direct clutch apply piston inner seal
14 — Direct clutch bushing hubs (part of 7F283) (2 required)
15 — Gear shaft tube sleeve (part of 7F283)
16 7F283 Direct clutch cylinder
17 7D020 Seal shell cylinders

Disassembly

  1. Remove and discard the 2 scarf cut seals and the roller bearing.
  1. Remove the T5 thrust bearing.
  1. Remove the direct clutch snap ring.
  1. Remove the direct clutch steel and friction plates.
  1. Install the Clutch Spring Compressors onto the direct clutch assembly.
  1. Using the Clutch Spring Compressors, compress the direct clutch return spring and remove the direct clutch return spring retainer.
  1. Remove the balance piston.
  1. Remove the direct clutch return spring.
  1. Remove the direct clutch piston.
  1. Remove and discard the outer O-ring seal from the balance piston.
  1. Remove and discard the outer and inner O-ring seals from the apply piston.
  1. Inspect the components of the direct clutch for damage. If damage is indicated, install new components as necessary.

Assembly

  1. Install a new inner and outer O-ring seal on the apply piston.
  1. Install a new outer O-ring seal on the balance piston.
  1. Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.
  1. Install the direct clutch return spring.
  1. Install the balance piston.
  1. Install the Clutch Spring Compressors onto the direct clutch assembly.
  1. Using the Clutch Spring Compressors, compress the direct clutch return spring and install the direct clutch return spring retainer.

  1. 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 portion of this section.

    Soak the new direct clutch in clean transmission fluid.
  1. Install the new direct clutch plates, starting with the wave spring then a steel plate and alternating between steel and friction plates, and ending with the pressure plate on the top.
  1. Install the direct clutch snap ring.

  1. NOTE: Inspect and install a new thrust bearing as required.

    Install the T5 thrust bearing.

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

    Install the direct clutch assembly into the Clutch End Play Gauge and install the Dial Indicator Gauge with Holding Fixture and position the plunger so it fits into the opening of the snap ring.
  1. 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.
  1. 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.

    Description Reading
    Reading A  
    Reading B  
    Add reading A to reading B for a total end clearance  
    Divide the total reading by 2 for an average end clearance  

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

    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.
  1. Install 2 new scarf cut seals and the roller bearing.