Ford Focus Service Manual: Forward Clutch

	Compressor, Spring Washer 307-209
	Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C)

Disassembly

1. Remove the forward clutch pressure, friction and steel plates.
   1. Remove the retaining ring.
   1. Remove the plates.

1. Using the Spring Washer Compressor, install the forward clutch assembly in a suitable press.

1. Using the Spring Washer Compressor, remove the forward clutch balance piston snap ring.

1. NOTICE: If damage to the forward clutch balance piston seals is found, install a new balance piston.

   Remove and inspect the forward clutch balance piston.

1. Remove the forward piston return spring.

1. NOTICE: If damage is found to the forward clutch piston seals, install a new forward clutch piston.

   Remove the forward clutch piston assembly.

Assembly

1. Soak the internal spline clutch plates in clean transmission fluid.

1. Inspect the forward clutch piston bore surfaces for nicks or scratches. Install a new balance piston if necessary.

1. Lubricate and install the forward clutch piston assembly.

1. Install the forward piston return spring.

1. Lubricate and install the forward clutch balance piston.

1. Using the Spring Washer Compressor, install the forward clutch assembly in a suitable press.

1. Using the Spring Washer Compressor, install the forward clutch balance piston snap ring.

1. Install the forward clutch pressure, friction and steel plates.
   1. Install the plates.
   1. Install the retaining ring.

1. Measure the clutch pack clearance.
   1. Install the forward clutch on the pump assembly.
   1. Install the Dial Indicator Gauge With Holding Fixture on the pump assembly and position the Dial Indicator plunger on the pressure plate.
   1. Using a suitable tool, lift up on both sides of the clutch pack and measure and record the clutch pack clearance on the Dial Indicator in 3 different areas. Average the measurements.

1. Compare the forward clutch pack clearance to the specification (1.5-1.8 mm [0.059-0.07 in]). If the clutch pack clearance is not within specification, select and install the correct size retaining ring to obtain the specified clearance.
   
   
   

   Part Number	Thickness
   —	1.15-1.25 mm (0.045-0.049 in)
   —	1.35-1.45 mm (0.053-0.057 in)
   —	1.55-1.65 mm (0.061-0.064 in)
   —	1.75-1.85 mm (0.068-0.072 in)
   —	1.95-2.05 mm (0.076-0.080 in)
   —	2.15-2.25 mm (0.084-0.088 in)