Overdrive Brake and Coast Clutch Drum Assembly: Disassembly

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.

Remove the coast clutch pressure plate.
1. Remove the coast clutch retaining ring.
2. Remove the coast clutch pressure plate.
  
  Fig 1: Removing Coast Clutch Pressure Plate
  Courtesy of FORD MOTOR CO.
Remove the coast clutch disc pack.
- Inspect for wear, install a new pack as necessary.
  
  Fig 2: Identifying Coast Clutch Disc Pack
  Courtesy of FORD MOTOR CO.

WARNING: Use caution when releasing tool pressure on the rear clutch piston spring. Failure to follow these instructions may result in personal injury.

CAUTION: Do not fully compress the special tool or damage to the spring retainer may occur.

Fig 3: Removing Coast Clutch Piston Retaining Ring

Courtesy of FORD MOTOR CO.

Using the special tool, remove the coast clutch piston retaining ring.
Relieve the coast clutch spring tension and remove the special tool.
Remove the coast clutch piston springs.
1. Remove the coast clutch piston retainer.
2. Remove the clutch piston springs.
  
  Fig 4: Removing Clutch Piston Springs
  Courtesy of FORD MOTOR CO.

WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air and make sure the drum is facing down as shown in Fig 5. Failure to follow these instructions may result in personal injury.

Remove the coast clutch piston.
- Apply air pressure to the hole in the drum to remove the coast clutch piston while blocking the other hole with a finger.
  
  Fig 5: Removing Coast Clutch Piston
  Courtesy of FORD MOTOR CO.
Remove and discard the coast clutch piston inner seal and the coast clutch piston outer seal.

Fig 6: Identifying Coast Clutch Piston Inner And Outer Seals
Courtesy of FORD MOTOR CO.