Sun Gear Shell Assembly: Reassembly
- Ensure forward, direct and intermediate clutch assemblies have been checked and overhauled as necessary before reassembling shell assembly. Position shell with intermediate clutch facing down. Ensure thrust washer No. 7 tabs are aligned with slots in direct clutch.
- Install one-way clutch on direct clutch, with clutch lip facing down and lip on outer race facing up. Outer race should turn clockwise and lock counterclockwise when direct clutch is facing up. See Figure. Install direct and intermediate clutch hub "O" ring seals on hub.
- Install forward clutch assembly, being careful not to damage "O" rings. Install thrust washer No. 6 on forward clutch assembly locking thrust washer tabs into oval holes on spring and support assembly. Ensure low one-way clutch is positioned in overdrive drum. Low one-way clutch should turn counterclockwise. See Figure. Position overdrive drum over forward clutch. See Figure.
- Turn assembly over and set on overdrive drum. Install thrust bearing No. 10 onto intermediate clutch hub. Use petroleum jelly to hold bearing in position.
- Install intermediate clutch hub into forward clutch. Install thrust bearing No. 11 on intermediate clutch hub with outer lip facing down. Install sun gear and shell assembly over direct/intermediate clutch assembly. Ensure tabs of sun gear shell and overdrive drum align.
- Install NEW driven sprocket support teflon seals. Using slide hammer to remove and press to install, replace driven sprocket support bearing, as necessary. Install thrust washer No. 5 on support. Use petroleum jelly to hold thrust washer in position.
- Turn assembly over onto front sun gear and shell assembly. Install driven sprocket support into overdrive drum. Using air pressure, apply about 40 psi to each clutch port. See Fig 1. If air can be heard leaking past seals, seals were damaged during assembly and must be replaced. Remove driven sprocket support from overdrive drum.
Courtesy of FORD MOTOR CO.