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Coast Clutch Assembly: Disassembly

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.
  1. Remove the No. 5 thrust bearing.
    Fig 1: Locating No. 5 Thrust Bearing
    G03889395Courtesy of FORD MOTOR CO.
  2. Remove the retaining ring and remove the center shaft.
    Fig 2: Locating Center Shaft
    G04649929Courtesy of FORD MOTOR CO.
  3. Remove the overdrive planetary No. 4 thrust bearing.
    Fig 3: Locating No. 4 Thrust Bearing
    G03889397Courtesy of FORD MOTOR CO.
  4. Remove the retaining ring.
    Fig 4: Locating Retaining Ring
    G03889398Courtesy of FORD MOTOR CO.
  5. Remove the coast clutch pressure plate one-way clutch (OWC) (mechanical diode) assembly and the clutch plates.
    Fig 5: Locating Clutch Pressure Plate
    G04649932Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the coast clutch return spring retaining ring.
    Fig 6: Identifying Coast Clutch Return Spring Retaining Ring With Special Tools
    G04649933Courtesy of FORD MOTOR CO.
  7. Remove the coast clutch return spring.
    Fig 7: Locating Coast Clutch Return Spring
    G03889401Courtesy of FORD MOTOR CO.
  8. Remove and discard the coast clutch piston and seal assembly.
    Fig 8: Identifying Coast Clutch Piston And Seal Assembly
    G04649935Courtesy of FORD MOTOR CO.
    9. NOTE: If the teeth and/or bushing are damaged, a new sun gear will need to be installed.
    Fig 9: Identifying Sun Gear
    G04649936Courtesy of FORD MOTOR CO.
  9. If required, use an arbor press to remove the sun gear.
    10. NOTE: If the coast clutch cylinder assembly shows any signs of damage, install a new coast clutch cylinder.
  10. 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: Identifying Coast Clutch Cylinder Assembly
      G04649937Courtesy of FORD MOTOR CO.
    11. NOTE: If the coast clutch hub shows any signs of damage, install a new coast clutch hub.
  11. Inspect the OWC inner race.
  12. Remove and discard the retaining bolts for the coast clutch hub. Separate the 2 halves.
    Fig 11: Locating Coast Clutch Hub And Bolts
    G04649938Courtesy of FORD MOTOR CO.
  13. Inspect the planet gears for damage. If any damage is found, install a new overdrive planet.
    Fig 12: Identifying Planet Gears
    G04649939Courtesy of FORD MOTOR CO.
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