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

Intermediate Clutch Assembly


Special Tool(s)
Compressor, Clutch Spring
307-525
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

Intermediate Clutch Assembly

Item Part Number Description
1 7D483 Center support retaining ring
2 7D483 Intermediate clutch pack retaining ring
3 7B066 Intermediate clutch pressure plate
4 7B164 Intermediate clutch internal splined friction plates (quantity model dependent)
5 7B442 Intermediate clutch external splined steel plates (quantity model dependent)
6 7E085 Intermediate clutch cushion spring
7 7A577 Intermediate clutch snap ring
8 7B043 Intermediate clutch return spring retaining ring
9 7A480 Intermediate clutch piston return spring
10 7E005 Intermediate clutch piston (model dependant)
11 7F225 Intermediate clutch piston inner seal
12 7F224 Intermediate clutch piston outer seal
13 7F373 Bearing (T6)
14 7A130 Intermediate/low/reverse clutch center support
15 7G199 Center support seals (2 — 7G199, 1 — 7G087, 1 — 7G484)

Disassembly

NOTICE: The intermediate clutch plate quantity is model dependent on engine size. Check the clutch plate quantity charts in specifications for the correct clutch plate quantity. Failure to install the correct clutch plate quantity will result in transmission failure.

NOTICE: The intermediate clutch piston is model dependent on engine size due to the different quantity of intermediate clutch plates. If installing a new intermediate clutch piston, check to make sure the height of the new piston is the same as the original piston. Failure to install the correct piston will result in transmission failure.

  1. Remove the T6 thrust bearing.
  1. Remove the intermediate clutch plate snap ring.
  1. Remove the intermediate clutch plates.
  1. Using the Clutch Spring Compressor, remove and discard the intermediate clutch return spring retainer.
  1. Remove the intermediate clutch return spring top plate.
  1. Remove the intermediate clutch return spring.
  1. Applying a slight amount of air to the port, remove the intermediate clutch piston.
  1. 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.
  1. Lightly coat the O-ring seals in clean automatic transmission fluid and install the intermediate clutch piston.
  1. Install the intermediate clutch return spring.
  1. Install the intermediate clutch return spring top plate.
  1. Using the Clutch Spring Compressor, install a new intermediate 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 intermediate clutch plates in clean automatic transmission fluid.
  1. 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.
  1. Install the intermediate clutch plate snap ring.

  1. 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 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 intermediate 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 the T6 thrust bearing.