31/12/22, 10:26 Printer Friendly View
YMMS: 2010 Ford Explorer Sport Trac Dec 31, 2022
Engine: 4.6L Eng License:
VIN: Odometer:
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES > DIRECT CLUTCH
ASSEMBLY > DIRECT CLUTCH ASSEMBLY
Fig 1: Exploded View Of Direct Clutch Assembly
Courtesy of FORD MOTOR CO.
PARTS DESCRIPTION CHART
Item Part Number Description
1 7D483 Direct clutch pressure plate retaining ring
2 7B066 Direct clutch pressure plate (quantity model dependant)
3 7B164 Direct clutch internal splined friction plates (quantity model dependant)
4 7B442 Direct clutch external splined steel plates
5 - Direct clutch cushion plate (wave spring)
[Link] 1/28
31/12/22, 10:26 Printer Friendly View
6 7C096 Bearing (T5)
7 7A577 Piston retaining ring
8 7A262 Direct clutch balance piston
9 7A548 Direct clutch balance piston seal
10 7B488 Return spring
11 7A262 Direct clutch apply piston
12 7A548 Direct clutch apply piston outer seal
13 7C099 Direct clutch apply piston inner seal
14 - Direct clutch bushing hubs (part of 7F283) (2 required)
15 - Gear shaft tube sleeve (part of 7F283)
16 7F283 Direct clutch cylinder
17 7D020 Seal shell cylinders
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES > DIRECT CLUTCH
ASSEMBLY > DISASSEMBLY
NOTE: Clutch plate quantity is model dependant based on
engine displacement:
4.6L engine (Explorer, Mountaineer, Sport Trac, F-150)
Four friction plates
Five steel plates
5.4L engine (Expedition, Navigator, F-150)
Five friction plates
Six steel plates
1. Remove and discard the 2 scarf cut seals and the roller bearing.
[Link] 2/28
31/12/22, 10:26 Printer Friendly View
Fig 1: Removing Scarf Cut Seals And Roller Bearing
Courtesy of FORD MOTOR CO.
2. Remove the T5 thrust bearing.
[Link] 3/28
31/12/22, 10:26 Printer Friendly View
Fig 2: Locating T5 Thrust Bearing
Courtesy of FORD MOTOR CO.
3. Remove the direct clutch snap ring.
[Link] 4/28
31/12/22, 10:26 Printer Friendly View
Fig 3: Locating Direct Clutch Snap Ring
Courtesy of FORD MOTOR CO.
4. Remove the direct clutch steel and friction plates.
[Link] 5/28
31/12/22, 10:26 Printer Friendly View
Fig 4: Locating Direct Clutch Steel And Friction Plates
Courtesy of FORD MOTOR CO.
5. Install the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015 onto the
direct clutch assembly.
[Link] 6/28
31/12/22, 10:26 Printer Friendly View
Fig 5: Identifying Clutch Spring Compressor And Onto Direct Clutch Assembly
Courtesy of FORD MOTOR CO.
6. Using the Clutch Spring Compressor 307-552 and Clutch Spring Compressor 307-015, compress the
direct clutch return spring and remove the direct clutch return spring retainer.
[Link] 7/28
31/12/22, 10:26 Printer Friendly View
Fig 6: Identifying Clutch Spring Conmpressor And Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
7. Remove the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015.
[Link] 8/28
31/12/22, 10:26 Printer Friendly View
Fig 7: Identifying Clutch Spring Compressor And Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
8. Remove the balance piston.
[Link] 9/28
31/12/22, 10:26 Printer Friendly View
Fig 8: Locating Balance Piston
Courtesy of FORD MOTOR CO.
9. Remove the direct clutch return spring.
[Link] 10/28
31/12/22, 10:26 Printer Friendly View
Fig 9: Locating Direct Clutch Return Spring
Courtesy of FORD MOTOR CO.
10. Remove the direct clutch piston.
[Link] 11/28
31/12/22, 10:26 Printer Friendly View
Fig 10: Locating Direct Clutch Piston
Courtesy of FORD MOTOR CO.
11. Remove and discard the outer O-ring seal from the balance piston.
[Link] 12/28
31/12/22, 10:26 Printer Friendly View
Fig 11: Removing Outer O-Ring Seal
Courtesy of FORD MOTOR CO.
12. Remove and discard the outer and inner O-ring seals from the apply piston.
[Link] 13/28
31/12/22, 10:26 Printer Friendly View
Fig 12: Removing Outer And Inner O-Ring Seals
Courtesy of FORD MOTOR CO.
13. Inspect the components of the direct clutch for damage. If damage is indicated, install new
components as necessary.
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES > DIRECT CLUTCH
ASSEMBLY > ASSEMBLY
[Link] 14/28
31/12/22, 10:26 Printer Friendly View
1. Install a new inner and outer O-ring seal on the apply piston.
Fig 1: Locating Apply Piston O-Ring Seal
Courtesy of FORD MOTOR CO.
2. Install a new outer O-ring seal on the balance piston.
[Link] 15/28
31/12/22, 10:26 Printer Friendly View
Fig 2: Installing Outer O-Ring Seal On Balance Piston
Courtesy of FORD MOTOR CO.
3. Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.
[Link] 16/28
31/12/22, 10:26 Printer Friendly View
Fig 3: Locating Direct Clutch Piston
Courtesy of FORD MOTOR CO.
4. Install the direct clutch return spring.
[Link] 17/28
31/12/22, 10:26 Printer Friendly View
Fig 4: Locating Direct Clutch Return Spring
Courtesy of FORD MOTOR CO.
5. Install the balance piston.
[Link] 18/28
31/12/22, 10:26 Printer Friendly View
Fig 5: Locating Balance Piston
Courtesy of FORD MOTOR CO.
6. Install the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015 onto the
direct clutch assembly.
[Link] 19/28
31/12/22, 10:26 Printer Friendly View
Fig 6: Identifying Clutch Spring Compressor And Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
7. Using the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015, compress
the direct clutch return spring and install the direct clutch return spring retainer.
[Link] 20/28
31/12/22, 10:26 Printer Friendly View
Fig 7: Identifying Clutch Spring Compressor And Clutch Spring Compressor
Courtesy of FORD MOTOR CO.
NOTE: Friction and steel plate quantity will vary based on
engine displacement. For additional information, refer to the
CLUTCH PLATE QUANTITY CHART .
[Link] 21/28
31/12/22, 10:26 Printer Friendly View
Fig 8: Identifying Direct Clutch
Courtesy of FORD MOTOR CO.
8. Soak the new direct clutch in clean transmission fluid.
9. Install the new direct clutch plates, starting with the wave spring then a steel plate and alternating
between steel and friction plates, and ending with the pressure plate on the top.
[Link] 22/28
31/12/22, 10:26 Printer Friendly View
Fig 9: Locating Direct Clutch Steel And Friction Plates
Courtesy of FORD MOTOR CO.
10. Install the direct clutch snap ring.
[Link] 23/28
31/12/22, 10:26 Printer Friendly View
Fig 10: Locating Direct Clutch Snap Ring
Courtesy of FORD MOTOR CO.
NOTE: Inspect and install a new thrust bearing as
required.
[Link] 24/28
31/12/22, 10:26 Printer Friendly View
Fig 11: Locating T5 Thrust Bearing
Courtesy of FORD MOTOR CO.
11. Install the T5 thrust bearing.
NOTE: All direct clutch plates, friction and steel are of a
wave-type design.
[Link] 25/28
31/12/22, 10:26 Printer Friendly View
Fig 12: Identifying Clutch End Play Gauge And Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
12. Install the direct clutch assembly into the Clutch End Play Gauge 307-555 and install the Dial
Indicator Gauge with Holding Fixture 100-002 and position the plunger so it fits into the opening of
the snap ring.
13. With the Dial Indicator Gauge set at zero, lift up on the steel pressure plate so it is against the select
fit snap ring. Record this reading as reading A.
[Link] 26/28
31/12/22, 10:26 Printer Friendly View
Fig 13: Lifting Up On Steel Pressure Plate
Courtesy of FORD MOTOR CO.
14. Rotate the direct clutch assembly 180 degrees from the opening of the snap ring, take a second
reading and record this reading as reading B.
READING DESCRIPTION REFERENCE
Description Reading
Reading A
Reading B
Add reading A to reading B for a total end clearance
Divide the total reading by 2 for an average end clearance
15. NOTE: If the final measurement is not within specification,
install a new snap ring until the correct specification is
achieved.
1. 5.4L engine - 0.5-1.3 mm (0.019-0.051 in).
2. 4.6L engine - 0.5-1.3 mm (0.019-0.051 in).
If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate
is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the
[Link] 27/28
31/12/22, 10:26 Printer Friendly View
bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit
snap ring.
16. Install 2 new scarf cut seals and the roller bearing.
Fig 14: Locating Scarf Cut Seals And Roller Bearing
Courtesy of FORD MOTOR CO.
[Link] 28/28