Disassembly and 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.

Remove the one-way clutch pressure plate assembly.

Fig 1: Removing One-Way Clutch Pressure Plate Assembly
Courtesy of FORD MOTOR CO.
Remove the reverse clutch plates.

Fig 2: Removing Reverse Clutch Plates
Courtesy of FORD MOTOR CO.
Remove the No. 13 rear reverse planet thrust washer.

Fig 3: Removing Rear Reverse Planet Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the reverse clutch ring gear subassembly.

Fig 4: Removing Reverse Clutch Ring Gear Subassembly
Courtesy of FORD MOTOR CO.
Remove the No. 14 front reverse planet thrust washer.

Fig 5: Removing Front Reverse Planet Thrust Washer
Courtesy of FORD MOTOR CO.
Inspect the reverse planet assembly.
- The pins and shafts in the planet assemblies should be checked for loose fit or damage. Use a new planet assembly if either condition exists.
- Inspect the pinion gears for damaged or excessively worn teeth.
- Check for free rotation of the pinion gears.
- Check for damage in the overdrive planet assembly.
  
  Fig 6: Inspecting Reverse Planet Assembly
  Courtesy of FORD MOTOR CO.
Remove the No. 15 sun gear thrust bearing.

Fig 7: Removing Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the snap ring. Disassemble the reverse ring gear and hub assembly. Inspect the components for damage. If damaged, install new components.

Fig 8: Removing Snap Ring
Courtesy of FORD MOTOR CO.
To assemble, reverse the disassembly procedure.
- Lightly lubricate the thrust washers with petroleum jelly to hold them in place during assembly.
- The tabs on the thrust washers must engage the slots on the reverse planet assembly when installed.
- The snap ring tips must be facing down toward the output shaft hub and fully engaged in the groove.