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Front Brake and Coast Clutch Drum Assembly: Assembly

WARNING: This page is about a different car, the 2004 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 New Coast Clutch Piston Inner And Outer Seal
    G03975312Courtesy 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 Into Special Tool
    G03975313Courtesy 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.
    • Verify the check ball in the front band brake and coast clutch drum is free to move and clear of debris.
      Fig 3: Verifying Check Ball In Front Band Brake And Coast Clutch Drum Is Free To Move And Clear Of Debris
      G03975314Courtesy of FORD MOTOR CO.
  4. Carefully remove the coast clutch piston from the special tool.
    Fig 4: Removing Coast Clutch Piston From Special Tool
    G03975315Courtesy of FORD MOTOR CO.
    5. CAUTION: Care must be taken to prevent damage to the seals during installation.
    Fig 5: Installing Coast Clutch Piston Into Front Band Brake And Coast Clutch Drum
    G03975316Courtesy of FORD MOTOR CO.
  5. Install the coast clutch piston into the front band brake and coast clutch drum.
  6. 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
      G03975317Courtesy of FORD MOTOR CO.
    7. 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
    G03975318Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the coast clutch piston spring retainer ring.
  8. Relieve the direct clutch spring tension and remove the special tool.
    9. 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 automatic transmission fluid before assembly.
    Fig 8: Ensuring The Word "TOP" Is Facing Face Up
    G03975319Courtesy of FORD MOTOR CO.
  9. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.
  10. 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 And Friction Clutch Plates
    G03975320Courtesy of FORD MOTOR CO.
    11. CAUTION: The retaining ring is select fit.
  11. Install the coast clutch pressure plate.
    1. Install the clutch pressure plate.
    2. Install the original coast clutch retaining ring.
      Fig 10: Installing Coast Clutch Pressure Plate
      G03975321Courtesy of FORD MOTOR CO.
    12. 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.
  12. Air check the assembly.
    • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
      Fig 11: Air Checking Assembly
      G03975310Courtesy of FORD MOTOR CO.
  13. 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
      G03975323Courtesy of FORD MOTOR CO.
      COAST CLUTCH RETAINING RING THICKNESS CHART

      Part Number Thickness Diameter
      E860126-S 1.37 mm (0.0539 in) 130.1 mm (5.122 in)
      E860127-S 1.73 mm (0.0681 in) 130.1 mm (5.122 in)
      E860128-S 2.08 mm (0.0819 in) 130.1 mm (5.122 in)
      E860129-S 2.44 mm (0.0961 in) 130.1 mm (5.122 in)
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