Coast Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the No. 5 thrust bearing.

Fig 1: Removing Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the retaining ring and remove the center shaft.

Fig 2: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the overdrive planetary No. 4 thrust bearing.

Fig 3: Removing Overdrive Planetary Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the retaining ring.

Fig 4: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the coast clutch pressure plate one-way clutch (OWC) (mechanical diode) assembly and the clutch plates.

Fig 5: Removing Coast Clutch Pressure Plate One-Way Clutch
Courtesy of FORD MOTOR CO.
Using the special tool, remove the coast clutch return spring retaining ring.

Fig 6: Removing Coast Clutch Return Spring Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the coast clutch return spring.

Fig 7: Removing Coast Clutch Return Spring
Courtesy of FORD MOTOR CO.
Remove and discard the coast clutch piston and seal assembly.

Fig 8: Removing And Discarding Coast Clutch Piston And Seal Assembly
Courtesy of FORD MOTOR CO.

NOTE: If the teeth and/or bushing are damaged, a new sun gear will need to be installed.

Fig 9: Removing Sun Gear

Courtesy of FORD MOTOR CO.

If required, use an arbor press to remove the sun gear.

NOTE: If the coast clutch cylinder assembly shows any signs of damage, install a new coast clutch cylinder.

Inspect the coast clutch cylinder assembly.
1. Inspect the bushing.
2. Inspect the No. 1 thrust washer mating surface.
3. Inspect the lube hole.
  
  Fig 10: Inspecting Lube Hole
  Courtesy of FORD MOTOR CO.

NOTE: If the coast clutch hub shows any signs of damage, install a new coast clutch hub.

Inspect the one-way clutch inner race.
Remove and discard the retaining bolts for the coast clutch hub. Separate the two halves.

Fig 11: Removing And Discarding Retaining Bolts For Coast Clutch Hub
Courtesy of FORD MOTOR CO.
Inspect the planet gears for damage. If any damage is found, install a new overdrive planet.

Fig 12: Inspecting Planet Gears For Damage
Courtesy of FORD MOTOR CO.