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.
2007 Ford Expedition 4WDFACTORY OEM SERVICE PROCEDURE
Direct Clutch Assembly: Notes
Special Tools
| Illustration | Tool Name | Tool Number |
|---|---|---|
| Dial Indicator Gauge with Holding Fixture | 100-002 (TOOL-4201-C) or equivalent | |
| Compressor, Clutch Spring | 307-015 (T65L-77515-A) | |
| Clutch Pack End Play Gauge | 307-555 | |
| Direct Clutch Pack Service Fixture | 307-552 |
Material
| Item | Specification |
|---|---|
| MERCON® SP Automatic Transmission Fluid XT-6-QSP (US); CXT-6-LSP12 (Canada) |
MERCON® SP |
| Item | Part Number | Description |
|---|---|---|
| 1 | 7B421 | Direct clutch pressure plate retaining ring |
| 2 | 7B447 | Direct clutch pressure plate |
| 3 | 7B164 | Direct clutch internal splined friction plates |
| 4 | 7E314 | Direct clutch external splined steel plates |
| 5 | - | Direct clutch cushion plate (wave spring) |
| 6 | 7D283 | Bearing (T5) |
| 7 | 7H363 | Direct clutch balance piston snap ring |
| 8 | 7D427 | Direct clutch piston spring retaining ring |
| 9 | 7B488 | Return spring |
| 10 | 7B488 | Piston retaining ring |
| 11 | 7H359 | Direct clutch balance piston |
| 12 | 7C000 | Direct clutch balance piston seal |
| 13 | 7F254 | Direct clutch apply piston |
| 14 | 7C000 | Direct clutch apply piston outer seal |
| 15 | 7F234 | Direct clutch apply piston inner seal |
| 16 | 7F240 | Direct clutch bushing hubs (2 required) (part of 7F281) |
| 17 | 7C486 | Gear shaft tube sleeve |
| 18 | 7F281 | Direct clutch cylinder |
| 19 | 7B399 | Seal shell cylinders |
Factory Service Tools
Use the Manual With the Right Hardware
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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.
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