Section 07-01: Transmission, Automatic—AODE
1994 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Reverse Clutch



Disassembled View





Item Part Number Description
1 7D044 Reverse Clutch Drum
2 7D256 Reverse Clutch Piston Spring Pressure Ring
3 7B070 Reverse Clutch Piston Spring
4 7B442 Reverse Clutch External Spline Clutch Plate
5 7B066 Clutch Pressure Plate
6 7G008 Forward Clutch Bearing
7 7D483 Clutch Pressure Plate Retainer Snap Ring
8 7B164 Reverse Clutch Internal Spline (Friction) Plates
9 7B066 Clutch Pressure Plate
10 7A577 Clutch Pressure Plate Retainer Snap Ring
11 7D404 Reverse Clutch Piston Small Seal
12 7D402 Reverse Clutch Piston
13 7D403 Reverse Clutch Piston Outer Seal


SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Clutch Spring Compressor T65L-77515-A
Reverse Clutch Spring Compressor T80L-77405-A
Reverse Clutch (Inner) Seal Protector T80L-77403-B
Reverse Clutch (Outer) Seal Protector T80L-77403-A

 

Disassembly

  1. Remove No. 2 needle bearing.



  1. Remove clutch pressure plate retainer snap ring (7D483).



  1. Remove clutch pack.



  1. Install Reverse Clutch Spring Compressor T80L-77405-A and Spring Compressor T65L-77515-A onto reverse clutch drum (7D044). Tighten enough to compress reverse clutch piston spring (7B070). Remove clutch pressure plate retainer snap ring (7A577).



    NOTE: To aid in reverse clutch piston spring removal, it may be necessary to apply air pressure to the reverse clutch drum. Block the opposite hole with a finger.

  1. Remove reverse clutch piston (7D402), reverse clutch piston spring and reverse clutch piston spring pressure ring (7D256).



  1. Remove reverse clutch piston and reverse clutch piston small seal (7D404) and reverse clutch piston outer seal (7D403).



 

Assembly

 

NOTE: The piston check ball must be present and moving freely.

  1. Install new reverse clutch piston small seal and reverse clutch piston outer seal on reverse clutch piston. Direction of installation is not important because seals are square cut.



    NOTE: Coat reverse clutch piston outer seal and reverse clutch piston small seal, reverse clutch drum, sealing area and seal protector with petroleum jelly.

  1. Install reverse clutch piston as follows:
    1. Install Reverse Clutch Seal Protector (Inner) T80L-77403-B on the clutch hub and Reverse Clutch Seal Protector (Outer) T80L-77403-A over the reverse clutch piston.
    1. Position reverse clutch piston and push it to the bottom of the reverse clutch drum using even thumb pressure.



  1. Install reverse clutch piston spring pressure ring and reverse clutch piston spring. The dished side of reverse clutch piston spring must face toward the reverse clutch piston.



  1. Install reverse clutch piston spring pressure ring (with points down) using Reverse Clutch Spring Compressor T80L-77405-A and Spring Compressor T65L-77515-A.



  1. Install front clutch pressure plate (7B066), clutch pack and rear clutch pressure plate. Position the stepped side of front clutch pressure plate down with flat side toward clutch pack and rear clutch pressure plate flat side toward clutch pack.



  1. Install clutch pack clutch pressure plate retainer snap ring and check the clearance between the clutch pressure plate retainer snap ring and the clutch pressure plate using a feeler gauge. Clutch pressure plate should be held downward as clearance is checked using Dial Indicator with Bracketry TOOL-4201-C or equivalent.



    The clearance should be:

    If clearance is not within specification, install correct size retaining ring and check clearance. Selective retaining rings are available in the following thicknesses:

    Selective Retaining Rings
    1.52-1.62mm (0.060-0.064 inch)
    1.87-1.98mm (0.074-0.078 inch)
    2.23-2.33mm (0.088-0.092 inch)
    2.59-2.69mm (0.102-0.106 inch)





  1. Check clutch for proper operation using Air Nozzle TOOL-7000-DE or equivalent. The clutch should be heard and felt to work smoothly and without leakage.