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.

Inspect the new coast clutch piston and seal assembly for damage and the check ball for free movement.

Fig 1: Identifying Coast Clutch Piston And Seal Assembly
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch piston.

Fig 2: Installing Coast Clutch Piston
Courtesy of FORD MOTOR CO.
Install the coast clutch return spring.

Fig 3: Installing Coast Clutch Return Spring
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch return spring retaining ring.

Fig 4: Installing Coast Clutch Return Spring Retaining Ring
Courtesy of FORD MOTOR CO.

NOTE: The OWC mechanical diode is also the coast clutch pressure plate.

Fig 5: Identifying OWC

Courtesy of FORD MOTOR CO.

Inspect the OWC for cracks and damaged splines. When installed correctly the internal splined portion of the OWC should rotate counterclockwise and lock when rotated clockwise. If any damage found or it does not rotate in the correct direction, install a new OWC.

NOTE: Inspect all separator and friction plates for damage. If any damage is found to any of the plates install new friction and separator plates.

NOTE: When installing the one-way clutch (OWC) (mechanical diode) the words "this side up" should be visible.

Fig 6: Installing Coast Clutch Pressure Plate One-Way Clutch (OWC)

Courtesy of FORD MOTOR CO.

Install the coast clutch pressure plate one-way clutch (OWC) (mechanical diode) assembly and the clutch plates starting with the separator plate.
Install the retaining ring.

Fig 7: Installing Retaining Ring
Courtesy of FORD MOTOR CO.
Check the stack-up clearance.
- 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.
- 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.
Assemble the overdrive planet to the coast clutch hub. Tighten bolts in the sequence shown in two stages.
- Stage 1: Tighten bolts to 30 Nm (22 lb-ft).
- Stage 2: Tighten bolts an additional 90 degrees.
  
  Fig 9: Tightening Bolts
  Courtesy of FORD MOTOR CO.
Install the coast clutch hub assembly into the coast clutch cylinder assembly.
Install the No. 4 thrust bearing and washer.

Fig 10: Installing Thrust Bearing And Washer
Courtesy of FORD MOTOR CO.

NOTE: When installing the retaining ring, make sure that it is completely seated in the groove with the tips down against the hub.

Fig 11: Installing Overdrive Ring Gear To Center Shaft

Courtesy of FORD MOTOR CO.

Install the overdrive ring gear to the center shaft and install the retaining ring.
Install the No. 5 thrust bearing.

Fig 12: Installing Thrust Bearing
Courtesy of FORD MOTOR CO.