Ford Mustang (1999-2004) Service Manual: Assembly

1. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly.

Using the special tool, install the inner piston seal.

  • Install the seal with sealing lip facing down.

Direct Clutch Disassembled View

2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder.

Direct Clutch Disassembled View

3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.

Using the special tool, install the direct clutch piston.

Direct Clutch Disassembled View

4. Install the piston return spring and retainer assembly.

5. Using the special tool, compress the piston return spring and install the retaining ring.

Direct Clutch Disassembled View

6. NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid for 15 minutes.

Install the clutch pack retaining ring.

1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.

2. Install the clutch pack retaining ring.

Direct Clutch Disassembled View

7. Use a feeler gauge to check the clearance between the clutch pack selective retaining ring and the pressure plate.

  • If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance.

Selective Retaining Ring

Selective Retaining Ring

 

Selective Retaining Ring

8. Install the direct clutch hub.

1. Install the No.7 direct clutch inner bearing support.

2. Install the direct clutch hub.

Selective Retaining Ring

NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear.

Inspect all bushings.

9. CAUTION: Make sure the seals are lapped correctly. Internal damage may occur.

Install the two direct clutch seal rings.

Selective Retaining Ring

10. Install the output shaft hub.

  • Position the output shaft hub.
  • Install the retaining ring.

Selective Retaining Ring

11. Install the three output shaft seal rings.

Selective Retaining Ring

12. Install the No. 8 needle bearing on the direct clutch cylinder.

Selective Retaining Ring

13. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub.

Assemble the direct clutch on the output shaft.

Selective Retaining Ring

14. CAUTION: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear.

Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft.

Selective Retaining Ring

    Disassembly
    1. NOTE: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear during the assembly procedure. Remove the ring gear snap ring. 2. Separate the ring gea ...

    Torque Converter (Disassembly and Assembly of Subassemblies)
    1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: A torque converter malfunction has been determined based on complete diagnostic ...

    Other materials:

    Universal Joints
    The universal joints are: lubed-for-life design and require no lubrication. equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearing and improve grease movement.   Item ...

    Valve Springs
    Special Tool(s) Compressor, Valve Spring 303-163 (T81P-6513-A) Material Removal 1. Remove the LH and the RH valve covers. For additional information, refer to Valve Cover-LH and Valve Cover RH in this section. 2. Rotate the crankshaft un ...

    Rear Bumper Cover
    Removal and Installation 1. Remove the luggage compartment trim panel covers. 2. Remove the seven rear bumper cover nuts. 3. Remove the fuel drain hose. 4. Remove the four bumper cover screws (two each side). 5. Remove the pin-type retainers and the rea ...