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Overdrive Brake and Coast Clutch Drum Assembly: Assembly

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The lip seals must be positioned as shown in Fig 1. Care must be taken to prevent rollover of the lip seal.
    Fig 1: Installing Coast Clutch Piston Inner And Outer Seal
    G03948992Courtesy of FORD MOTOR CO.
  1. Install the new coast clutch piston inner and outer seal.
  2. Verify the check ball is free to move.
    Fig 2: Ensuring Ball Moves Freely
    G03948993Courtesy of FORD MOTOR CO.
    3. CAUTION: Care must be taken to prevent damage to the seals during installation.
  3. Using the special tool, install the coast clutch piston.
    • Lubricate the seals with transmission fluid.
      Fig 3: Installing Coast Clutch Piston
      G03948994Courtesy of FORD MOTOR CO.
  4. Install the coast clutch piston springs.
    1. Install the coast clutch piston springs.
    2. Install the coast clutch spring retainer.
      Fig 4: Installing Coast Clutch Piston Springs
      G03948995Courtesy of FORD MOTOR CO.
    5. CAUTION: Do not fully compress the special tool or damage to the coast clutch piston spring retainer may occur.
    Fig 5: Installing Coast Clutch Piston Spring Retainer Ring
    G03948996Courtesy of FORD MOTOR CO.
  5. Using the special tool, install the coast clutch piston spring retainer ring.
    6. CAUTION: Coast clutch friction plates are directional and must be installed with grooves clockwise (ID to OD). 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 6: Identifying Coast Clutch Friction Plate Groove
    G03948997Courtesy of FORD MOTOR CO.
  6. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.
  7. Install the 2 steel clutch plates and 2 friction clutch plates in alternating order starting with a steel clutch plate.
    Fig 7: Installing Steel Clutch Plates And Friction Clutch Plates
    G03997530Courtesy of FORD MOTOR CO.
    8. CAUTION: The retaining ring is select fit.
  8. Install the coast clutch pressure plate.
    1. Install the coast clutch pressure plate.
    2. Install the original coast clutch retaining ring.
      Fig 8: Installing Original Coast Clutch Retaining Ring
      G03948999Courtesy of FORD MOTOR CO.
    9. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air and make sure drum is facing down as shown in Fig 9. Failure to follow these instructions may result in personal injury.
  9. Air check the assembly.
    • Apply air pressure to the hole in the drum while blocking the other hole with a finger.
      Fig 9: Applying Air Pressure To Hole In Drum While Blocking Other Hole With Finger
      G03948990Courtesy of FORD MOTOR CO.
  10. Check the coast clutch disc pack free play.
    1. Push down on the coast pressure plate.
    2. Check clearance between the coast clutch retaining ring and coast pressure plate. Clearance should be 1.3-2.0 mm (0.051-0.079 in). If clearance is not within the specification, install a correct coast clutch retaining ring that will provide the correct free play adjustment.
      COAST CLUTCH RETAINING RING PART NUMBER THICKNESS REFERENCE

      Part Number Thickness Diameter
      mm In mm In
      E860126-S 1.37 0.0539 130.1 5.122
      E860127-S 1.73 0.0681 130.1 5.122
      E860128-S 2.08 0.0819 130.1 5.122
      E860129-S 2.44 0.0961 130.1 5.122
      Fig 10: Checking Coast Clutch Disc Pack Free Play
      G03949001Courtesy of FORD MOTOR CO.
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