SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSFORD2005TAURUS SEL, 4D SEDANREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 345 (AUTOMATIC TRANSMISSION - CD4E)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESFORWARD/COAST/DIRECT CLUTCHESASSEMBLY
2005 Ford Taurus SEL, 4D Sedan

Forward/Coast/Direct Clutches: Assembly

2005 Ford Taurus SEL, 4D SedanSECTION Assembly
WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Soak the internal spline clutch plates in clean automatic transmission fluid.
  2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.
    Fig 1: Installing Forward Clutch Piston Inner Seal Using Special Tools
    G04620239Courtesy of FORD MOTOR CO.
  3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
    Fig 2: Locating Forward Clutch Piston Outer Lip Seal
    G04620240Courtesy of FORD MOTOR CO.
  4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
    Fig 3: Locating Forward Clutch Piston Assembly
    G04620241Courtesy of FORD MOTOR CO.
  5. Mark the center of 2 adjacent legs on the top of the cylinder.
    Fig 4: Locating Cylinder Mark
    G04620242Courtesy of FORD MOTOR CO.
  6. Find the center between the marks (45 degrees from either leg) and mark the cylinder.
    Fig 5: Locating Cylinder Marks
    G04620243Courtesy of FORD MOTOR CO.
  7. Install the coast clutch piston assembly onto the special tool.
    Fig 6: Installing Coast Clutch Piston Assembly Onto Special Tool
    G04620244Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.
    Fig 7: Installing Coast Clutch Piston Into Forward Clutch Piston Assembly Using Special Tools
    G04620245Courtesy of FORD MOTOR CO.
  9. Install the forward/coast clutch return spring assembly.
    Fig 8: Locating Clutch Return Spring Assembly
    G04620246Courtesy of FORD MOTOR CO.
    10. WARNING: While removing or installing the retaining ring, slowly release tool pressure on clutch piston springs. Failure to follow this instruction may cause the assembly to separate forcefully, resulting in serious personal injury.
  10. Install the forward/coast clutch return spring retaining ring.
    1. Using the special tool, compress the return spring.
    2. Install the forward/coast clutch retaining ring.
      • Orient the gap between the piston legs.
        Fig 9: Installing Clutch Return Spring Retaining Ring Using Special Tools
        G04620247Courtesy of FORD MOTOR CO.
  11. Install the forward and coast clutch plates in the sequence shown.
    1. Coast clutch external spline clutch plates (steel)
    2. Coast clutch internal spline clutch plates (friction)
    3. Coast clutch pressure plate
    4. Forward clutch wave spring
    5. Forward clutch internal spline clutch plates (friction)
    6. Forward clutch external spline clutch plates (steel)
    7. Forward clutch pressure plate
      Fig 10: Identifying Clutch Pressure Plate
      G04620248Courtesy of FORD MOTOR CO.
  12. Install the forward clutch pressure plate retaining ring.
    • Center the select fit retaining ring on the 45 degree mark between the 2 adjacent legs.
      Fig 11: Locating Clutch Pressure Plate Retaining Ring
      G04620249Courtesy of FORD MOTOR CO.
  13. Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring.
    • Take a second measurement on the opposite side.
    • Average the 2 measurements to get the clearance.
    • If the clearance is not within specification, select and install the correct thickness retaining ring to obtain the standard clearance.
    • Retaining ring sizes:
      • 1.43-1.53 mm (0.056-0.060 in).
      • 1.59-1.69 mm (0.062-0.066 in).
      • 1.75-1.85 mm (0.069-0.073 in).
      • 1.92-2.02 mm (0.075-0.079 in).
        Fig 12: Locating Retaining Ring Sizes:
        G04620250Courtesy of FORD MOTOR CO.
  14. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.
    Fig 13: Locating Clutch Piston Inner Lip Seal
    G04620251Courtesy of FORD MOTOR CO.
  15. Install the direct clutch piston outer seal on the direct clutch piston assembly.
    Fig 14: Locating Clutch Piston Outer Seal
    G04620252Courtesy of FORD MOTOR CO.
    16. NOTE: Position the lip seal facing down.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

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.