Coast Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

If the sun gear was removed, install the sun gear.

Fig 1: Installing Sun Gear
Courtesy of FORD MOTOR CO.

NOTE: If the coast clutch piston and seal assembly is damaged, install a new coast clutch piston and seal assembly.
Inspect the coast clutch piston and seal assembly for damage and the check ball for free movement.

Fig 2: Inspecting Coast Clutch Piston And Seal Assembly
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch piston.

Fig 3: Installing Coast Clutch Piston
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch retaining ring.
1. Install the return spring.
2. Install the retaining ring.
  
  Fig 4: Installing Coast Clutch Retaining Ring
  Courtesy of FORD MOTOR CO.
Make sure that the one-way clutch is locked in place. Turn counterclockwise to lock in place. Install the overdrive one-way clutch.

Fig 5: Installing Overdrive One-Way Clutch
Courtesy of FORD MOTOR CO.
Install the coast clutch pressure plate and the clutch plates.

Fig 6: Installing Coast Clutch Pressure Plate And Clutch Plates
Courtesy of FORD MOTOR CO.
Install the retaining ring.

Fig 7: Installing Retaining Ring
Courtesy of FORD MOTOR CO.
Check the stack-up clearance.
1. Using a feeler gauge, measure the stack up clearance in three places, 120 degrees apart, between the snap ring and the coast clutch pressure plate.
2. If the clearance is not within specification, install the correct coast clutch pressure plate retainer snap ring and recheck the clearance.
  
  Fig 8: Installing Correct Coast Clutch Pressure Plate Retainer Snap Ring
  Courtesy of FORD MOTOR CO.