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 SUBASSEMBLIESFORWARD CLUTCH ASSEMBLYASSEMBLY

2005 Ford Cutaway 5.4 L, 5R110W

Forward Clutch Assembly: Assembly

2005 Ford Cutaway 5.4 L, 5R110WSECTION Assembly

Lightly lubricate the new pistons and seals with clean automatic transmission fluid.
1. Forward clutch balance piston
2. Forward clutch balance piston return spring
3. Forward clutch piston
  
  Fig 1: Identifying Forward Clutch Piston
  Courtesy of FORD MOTOR CO.
Install the forward clutch piston.

Fig 2: Installing Forward Clutch Piston
Courtesy of FORD MOTOR CO.
Install the forward clutch balance piston return spring and balance piston.

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

Fig 4: Installing Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: Inspect the forward clutch plates for damage. If any damage is found, install new plates.

Install the forward clutch pack.
1. Cushion spring
2. Externally splined steel plates
3. Internally splined friction plates
4. Forward clutch pressure plate
  
  Fig 5: Inspecting Forward Clutch Plates For Damage
  Courtesy of FORD MOTOR CO.
Install the forward clutch snap ring.

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

Fig 7: Measuring Clearance Between Snap Ring And Pressure Plate
Courtesy of FORD MOTOR CO.
Install the No. 8 forward clutch thrust bearing, blue side up.

Fig 8: Installing Forward Clutch Thrust Bearing, Blue Side Up
Courtesy of FORD MOTOR CO.
Install the No. 7 thrust washer and two new seals.

Fig 9: Installing No. 7 Thrust Washer And Two New Seals
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.