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 MANUALSFORD2005CUTAWAY 5.4 L, 5R110WREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSAUTOMATIC TRANSMISSION - 5R110WDISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESDIRECT CLUTCH ASSEMBLYASSEMBLY

2005 Ford Cutaway 5.4 L, 5R110W

Direct Clutch Assembly: Assembly

2005 Ford Cutaway 5.4 L, 5R110WSECTION Assembly

Lightly lubricate the new pistons with petroleum jelly.
1. Direct clutch piston
2. Direct clutch return spring
3. Direct clutch balance piston
  
  Fig 1: Assembling Lubricate New Pistons With Petroleum Jelly
  Courtesy of FORD MOTOR CO.
Install a new direct clutch piston.

Fig 2: Locating Direct Clutch Piston
Courtesy of FORD MOTOR CO.
Install the direct clutch return spring and a new balance piston.

Fig 3: Installing Direct Clutch Return Spring And Balance Piston
Courtesy of FORD MOTOR CO.
Using the special tools, install the snap ring.

Fig 4: Identifying Snap Ring With Special Tools
Courtesy of FORD MOTOR CO.

NOTE: The direct clutch plates are installed in an alternating sequence, starting with an externally splined steel plate, then an internally splined friction plate, with the pressure plate on the top just under the snap ring.

Install the plates.
1. Externally splined steel plates
2. Internally splined friction plates
3. Pressure plate
  
  Fig 5: Installing Plates
  Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 6: Installing Snap Ring
Courtesy of FORD MOTOR CO.
Using a feeler gauge, measure the clearance between the snap ring and the pressure plate.

Fig 7: Measuring Clearance Between Snap Ring And Pressure Plate
Courtesy of FORD MOTOR CO.

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.