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Front Brake & Coast Clutch Drum Assembly: Assembly

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
    Fig 1: Installing Coast Clutch Piston Inner & Outer Seal
    G02152846Courtesy of FORD MOTOR CO.
  1. Install the new coast clutch piston inner and outer seal.
    2. CAUTION: Lubricate the coast clutch piston inner and outer seal.
    Fig 2: Installing Coast Clutch Piston Onto Special Tool
    G02152847Courtesy of FORD MOTOR CO.
  2. Install the coast clutch piston into the special tool.
  3. Inspect the coast clutch components for damage or wear. Install a new as necessary.
    • Inspect the drum band surface, bushing and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be installed as new.
    • Inspect the clutch piston bore and the clutch piston and the piston inner and outer bearing surfaces for scores.
    • Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
    • Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations. Install new plates that are badly scored, worn or do not fit freely in the hub serrations.
    • Inspect the clutch pressure plate for scores on the clutch plate surface. Check the clutch release spring(s) for distortion.
  4. Verify the check ball in the front band brake and coast clutch drum is free to move and clear of debris.
    Fig 3: Inspecting Check Ball In Front Band Brake
    G02152848Courtesy of FORD MOTOR CO.
  5. Carefully remove the coast clutch piston from the special tool.
    Fig 4: Removing Coast Clutch Piston From Special Tool
    G02152849Courtesy of FORD MOTOR CO.
    6. CAUTION: Care must be taken to prevent damage to the seals during installation.
    Fig 5: Installing Coast Clutch Piston Into Front Band Brake & Coast Clutch Drum
    G02152850Courtesy of FORD MOTOR CO.
  6. Install the coast clutch piston into the front band brake and coast clutch drum.
  7. Install the coast clutch piston springs.
    1. Install the twenty (20) coast clutch piston springs.
    2. Position the coast clutch piston spring retainer on the coast clutch piston springs.
    Fig 6: Installing Coast Clutch Piston Springs
    G02152851Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not fully compress the special tool or damage to the coast clutch piston spring retainer may occur.
    Fig 7: Installing Coast Clutch Piston Spring Retainer Ring
    G02152852Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the coast clutch piston spring retainer ring.
  9. Relieve the direct clutch spring tension and remove the special tool.
    10. CAUTION: Coast clutch friction plates are directional and must be installed with grooves clockwise (I.D. to O.D.). The word "TOP" should face up.
    CAUTION: If new clutch plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.
    Fig 8: Installing Friction Plates
    G02152853Courtesy of FORD MOTOR CO.
  10. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.
  11. Install the two steel clutch plates and two friction clutch plates in alternating order starting with a steel clutch plate.
    Fig 9: Installing Steel Clutch Plates & Friction Clutch Plates
    G02152854Courtesy of FORD MOTOR CO.
    12. CAUTION: The retaining ring is select fit.
    Fig 10: Installing Coast Clutch Pressure Plate
    G02152855Courtesy of FORD MOTOR CO.
  12. Install the coast clutch pressure plate.
    1. Install the clutch pressure plate.
    2. Install the original coast clutch retaining ring.
    13. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Make sure drum is facing down as shown. Failure to follow these instructions may result in personal injury.
    NOTE: The coast clutch piston is applied with air pressure and released when the air is removed.
    Fig 11: Air Checking Assembly
    G02152856Courtesy of FORD MOTOR CO.
  13. Air check the assembly.
    • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
  14. Check the coast clutch disc pack free play.
    1. Push down on the coast clutch pressure plate.
    2. Check clearance between the coast clutch retaining ring and coast clutch pressure plate. Clearance should be 1.3-2.0 mm (.051-.079 in). If clearance is not within the specification, install a new coast clutch retaining ring that will correct free play adjustment.
    Fig 12: Checking Coast Clutch Disc Pack Free Play
    G02152857Courtesy of FORD MOTOR CO.
    Fig 13: Coast Clutch Retaining Ring Specification Chart
    G02152858Courtesy of FORD MOTOR CO.
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