Clutch and Damper Unit

Removal

1. Refer to: Transmission - 2.0L Duratec-HE (125kW/170PS) - MI4 (307-01 Automatic Transmission - Vehicles With: 6-Speed PowerShift Transmission - DPS6/6DCT250) .
   

1. General Equipment : Wooden Block

1. Use part: -7064- clutch hub snap ring 71.5 X 2
   

1. NOTE: Note the position of the component before removal.

1. Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer

1. 1. NOTE: Only tighten the bolt finger tight at this stage.

   2. Using the special tools, turn the center bolt of the special tool with a maximum of 5 Nm (44 lb-in) of torque to push the clutch down to release the pressure from the hollow input shaft snap ring.
      Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer
      Torque : 5 Nm

1. Use part: -7064- hollow input shaft snap ring 35 X 1.8
   

1. NOTICE: Make sure the lifting legs are installed on the clutch studs marked with the stamped manufacturing mark as shown.

   NOTICE: Installing the lifting legs on unmarked clutch studs will damage the pressure plate adjuster.

   NOTICE: Make sure the lifting leg with the angle is in the location shown.

   Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer

1. Turn the center bolt with approximately 5 Nm (44 lb-in) of torque until the clutch is free of the input shaft.
   Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer
   Torque : 5 Nm

Installation

 A video version of this procedure is available on-line.

1. Click here to view clutch reset video.
   

1. NOTICE: New clutches are shipped with the clutch locks locked. Attempting to reset a locked clutch will damage the clutch. Steps 4 through 16 only apply if the clutch is unlocked.

   Verify clutch 2 locks are locked.
   

1. Verify clutch 1 locks are locked.
   

1. Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset
   General Equipment : Vise

1. NOTE: Only tighten the nut and bolt finger tight at this stage.

   Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. NOTE: Only tighten the nut and bolt finger tight at this stage.

   Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. Install the special tool on the clutch making sure the legs are inserted in the slots.
   Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

   1. Turn the special tool clockwise to the stops and hold.
      
   2. Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.
      Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. NOTE: Only tighten the nut finger tight at this stage.

   Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

   NOTE: An audible click can be heard when the clutch locks lock.

   While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to the stops on the clutch. The locks on clutch 2 lock at this time.
   Special Tool(s) : 307-676 Tool, Clutch 1 and 2 Reset

1. Remove Special Service Tool : 307-676 Tool, Clutch 1 and 2 Reset

1. NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as shown. If not, reset the clutch 2 locks as necessary.

   NOTE: 4 locks shown, 12 total.

   Visually check the locks to make sure they have locked.
   

1. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.
   

1. NOTE: This step does not need to be performed if a new clutch is being installed.

   NOTE: Use a 0-75mm caliper.

   Replace clutch if clearance is less than the specified value.
   General Equipment : Caliper Gauge

1. NOTE: This step does not need to be performed if a new clutch is being installed.

   Replace clutch if clearance is less than the specified value.
   General Equipment : Caliper Gauge

1. NOTICE: Do not tilt the transmission until after Step 28 when the clutch locks are released. Failure to do so may cause the Z-washers to fall out of place causing a noise issue or damage.

   NOTE: The component can only be installed in 1 position.

   NOTE: A small amount of adhesive is applied between the Z-washer and the bearing surface to aid factory assembly. This is NORMAL and not required in service during a repair.

1. NOTICE: Excessive oil can contaminate the clutch. Only apply enough oil to lubricate the shaft for clutch installation.

   Apply a thin coating.
   Material : Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. NOTICE: Excessive grease can contaminate the new clutch. Apply 1 gram or about 1/3 tube of the grease provided in the kit.

   Apply a small amount of DPS6 Grease on both input shaft splines.
   Material : DPS6 Grease / 9U7Z-19A506-BA (WSS-M1C270-A)

NOTICE: Do not tilt the transmission until after Step 26 when the clutch locks are released. Failure to do so may cause the Z-washers to fall out of place, causing a noise issue or damage.

1. NOTICE: Verify the clutch locks are locked prior to installation or the transaxle may not operate correctly and damage can occur. If the clutch locks are not locked go to step 4 within this procedure.

   NOTICE:

   NOTE: The clutch splines are properly aligned when the end of the hollow input shaft is near the clutch bearing centerline.

   Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer

1. Remove special tools.
   Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer

1. Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer

1. NOTICE: Do not overtighten the special tool or damage can occur.

   Special Tool(s) : 307-675 Fixture, Clutch Remover/Installer
   Torque : 5 Nm

1. NOTE: Make sure that a new component is installed.

   The snap ring ends are tapered for easier removal. Install the new snap ring with the narrow opening on top.
   

1. NOTE: Verify snap ring is secure in groove.

   • Special Tool(s) : 307-677 Socket, Actuator Reset
   • Or Use the General Equipment: Ball End Hex Bit - 6 mm.
     

1. NOTE: Make sure the installation marks are aligned.

1. NOTE: Make sure that a new component is installed.

   NOTE: The component can only be installed in 1 position.

1. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.
   Material : High Temperature Nickel Anti-Seize Lubricant / XL-2

1. Material : High Temperature Nickel Anti-Seize Lubricant / XL-2

1. NOTICE: Use only hand pressure to align the splines and seat the motor. Do not use the bolts to draw the motor to the case. Forcing the motor into the case will damage the clutch motor and engagement lever.

   NOTE: Clutch motor splines may need to be turned to ease installation.

1. Torque : 5 Nm

1. Refer to: Transmission - 2.0L Duratec-HE (125kW/170PS) - MI4 (307-01 Automatic Transmission - Vehicles With: 6-Speed PowerShift Transmission - DPS6/6DCT250) .
   

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