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 MANUALSFORD1996EXPLORER 4D UTILITY, 4.0 X, 4WD, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSOVERHAUL - 4R70W AUTOMATIC TRANSMISSIONCOMPONENT DISASSEMBLY & REASSEMBLYFORWARD CLUTCHREASSEMBLY
1996 Ford Explorer 4D Utility, 4.0 X, 4WD, Standard
Forward Clutch: Reassembly
1996 Ford Explorer 4D Utility, 4.0 X, 4WD, StandardSECTION Reassembly
- Lubricate and install inner and outer seals on piston with seal lips facing into clutch drum. Lubricate piston seals and drum sealing area with petroleum jelly. Install piston into drum using Seal Protector (T80L-77140-A) to prevent damaging seals.
- Position return spring and retainer on piston. Compress return spring and install retaining snap ring. Install clutch pack into clutch drum starting with waved spring. Install a steel plate and then a friction plate. Alternately install remaining plates in clutch pack. Install pressure plate and snap ring.
- Using a feeler gauge, measure clearance between retaining snap ring and pressure plate with pressure plate held down. If clearance is not .050-.089" (1.27-2.26 mm), install correct size snap ring and recheck clearance. Selective snap rings are available in the following sizes: .060-.064" (1.52-1.73 mm), .074-.078" (1.88-1.98 mm), .086-.092" (2.23-2.34 mm) and .102-.106" (2.59-2.69 mm).NOTE: Solid shaft seals may be replaced with scarf-cut seals if necessary.
- If original seals are damaged or missing, install NEW input shaft seals. Install No. 3 needle bearing. Install forward clutch hub into forward clutch cylinder and shaft. Ensure forward clutch hub is against No. 3 needle bearing.
RENDER: 1.0x
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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.