Eee 1
Eee 1
Eee 1
307-675
Fixture, Clutch Remover/Installer
TKIT-2010D-FLM
TKIT-2010D-ROW
307-676
Tool, Clutch 1 and 2 Reset
TKIT-2010D-FLM
TKIT-2010D-ROW
307-677
Socket, Actuator Reset
TKIT-2010D-FLM
TKIT-2010D-ROW
Wooden Block
Vise
Caliper Gauge
Materials
Name Specification
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
DPS6 Grease -
9U7Z-19A506-BA
Motorcraft® High Temperature Nickel Anti-Seize Lubricant -
XL-2
Motorcraft® Dual Clutch Transmission Fluid WSS-M2C200-D2
XT-11-QDC
Removal
3.
Remove the clutch actuator motor A.
1. Unlock the electrical connector.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
4.
Remove the clutch actuator motor B.
1. Unlock the electrical connector.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
Align the position of clutch assembly and remove the clutch hub.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
7. Install the special tool and inspect the proper alignment with clutch assembly.
Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
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.
Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
Torque: 44 lb.in (5 Nm)
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
10. 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.
Install the special tool , making sure the lifting legs are installed on the clutch studs marked with the stamped
manufacturing mark as shown.
Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
11. Turn the center bolt with approximately 5 Nm (44 lb-in) of torque until the clutch is free of the input shaft.
Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
Torque: 44 lb.in (5 Nm)
12. Clean the transmission input shaft splines and clutch release bearing mounting surface.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
Installation
2. NOTICE: New clutches are shipped with the clutch locks locked. Attempting to reset a locked clutch
will damage the clutch. Steps 4 through 16 apply only if the clutch is unlocked.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
5. NOTE: Only tighten the nut and bolt finger tight at this stage.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
6. NOTE: Only tighten the nut and bolt finger tight at this stage.
7. Install the special tool on the clutch making sure the legs are inserted in the slots.
Use Special Service Tool: 307-676 Tool, Clutch 1 and 2 Reset.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
8. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch causes damage
to the clutch.
2. Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.
Use Special Service Tool: 307-676 Tool, Clutch 1 and 2 Reset.
10. NOTE: Only tighten the nut finger tight at this stage.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
12. 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.
Use Special Service Tool: 307-676 Tool, Clutch 1 and 2 Reset.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
13. Remove Special Service Tool: 307-676 Tool, Clutch 1 and 2 Reset.
14. 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.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
15. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch
wear.
16. NOTE: This step does not need to be performed if a new clutch is being installed.
17. NOTE: This step does not need to be performed if a new clutch is being installed.
18. 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.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
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.
19. NOTICE: Excessive oil can contaminate the clutch. Only apply enough oil to lubricate the shaft for
clutch installation.
20. NOTICE: Excessive grease can contaminate the new clutch. Apply 1 gram or about 1/3 tube of the
grease provided in the kit.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
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.
21. 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.
Turn the center bolt with approximately 5 Nm (44 lb-in) of torque until the clutch is engaged to the input shaft.
Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
24. NOTICE: Do not overtighten the special tool or damage can occur.
Press the clutch bearing down far enough to install the snap ring in the groove.
Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer.
Torque: 44 lb.in (5 Nm)
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
The snap ring ends are tapered for easier removal. Install the new snap ring with the narrow opening on top.
Using the special tool, turn the transmission shaft counterclockwise until an audible click is heard.
Use Special Service Tool: 307-677 Socket, Actuator Reset.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
Align the position of the clutch assembly and install the clutch hub.
Install a new clutch hub snap ring and align with marking.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
29. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.
Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2
30. Apply High Temperature Nickel Anti-Seize Lubricant to the transmission housing surfaces where indicated.
Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
31. 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.
Install the clutch actuator motors in the transmission case and make sure they rest against the case all the way.
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12/26/2020 Automatic Transmission - 6-Speed PowerShift Transmission - DPS6/6DCT250 - Clutch and Damper Unit - Removal and Installation • 20…
34.
Connect and lock the electrical connectors.
1. Connect the clutch actuator motor electrical connectors.
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