Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1996BRONCO 5.0 N, AUTOMATIC, E4ODREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSAUTOMATIC TRANSMISSION - OVERHAUL - E4OD AUTOMATIC TRANSMISSIONCOMPONENT DISASSEMBLY & REASSEMBLYDIRECT CLUTCH ASSEMBLYREASSEMBLY
1996 Ford Bronco 5.0 N, Automatic, E4OD
Direct Clutch Assembly: Reassembly
1996 Ford Bronco 5.0 N, Automatic, E4ODSECTION Reassembly
- Install inner and outer seals in cylinder with seal lips facing down into cylinder. Inspect piston check ball for freedom of movement. Install piston into drum.
- Ensure piston rotates freely in cylinder. Install return spring. Ensure protrusions on spring retainer are properly engaged with lugs on clutch piston. Use spring compressor and compress springs. Install retaining ring.
- Install clutch pack, first using a steel plate and then a friction plate. Install pressure plate and secure pack with selective retaining ring.
- Using a feeler gauge, check clearance between retaining ring and pressure plate. Ensure clearance is .045-.081" (1.15-2.06 mm).
- If clearance is not within specifications, install correct snap ring. Selective snap rings are available in thicknesses of .056-.060" (1.42-1.53 mm), .065-.069" (1.65-1.75 mm), .074-.078" (1.88-1.98 mm) and .083-.087" (2.11-2.21 mm). Install correct size snap ring and recheck clearance.
- Install small brass thrust washer and large brass thrust washer on face of cylinder. Install intermediate one-way clutch end cap, one-way clutch assembly, and bottom end cap into outer race. Lip faces upward on one-way clutch.
- Install outer race and one-way clutch assembly onto inner race to ensure race turns counterclockwise. Install thrust washer on intermediate brake drum face.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.