Coast Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 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 Check Ball
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch piston.

Fig 2: Identifying Coast Clutch Piston With Special Tools
Courtesy of FORD MOTOR CO.
Install the coast clutch return spring.

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

Fig 4: Identifying Coast Clutch Return Spring Retaining Ring With Special Tools
Courtesy of FORD MOTOR CO.

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

NOTE: Gas applications use a unique mechanical diode from diesel applications.

Fig 5: Identifying Coast Clutch Pressure Plate

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 is found or if 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 OWC (mechanical diode), the words "this side up" should be visible.

Fig 6: Locating Coast Clutch Pressure Plate

Courtesy of FORD MOTOR CO.

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

Fig 7: Locating Retaining Ring
Courtesy of FORD MOTOR CO.
Check the stack-up clearance.
- Using a feeler gauge, measure the stack-up clearance in 3 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: Identifying Coast Clutch Pressure Plate Clearance Specification
  Courtesy of FORD MOTOR CO.
Assemble the overdrive planet to the coast clutch hub. Tighten bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 9: Identifying Tightening Sequence For Coast Clutch Hub 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: Locating No. 4 Thrust Bearing
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: Identifying Retaining Ring Groove Make

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: Locating No. 5 Thrust Bearing
Courtesy of FORD MOTOR CO.