Coast Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

If the sun gear was removed, install the sun gear.

Fig 1: Installing Sun Gear
Courtesy of FORD MOTOR CO.
Inspect the coast clutch piston and seal assembly for damage and the check ball for free movement.
If the coast clutch piston and seal assembly is damaged it will need to be replaced.

Fig 2: Inspecting Coast Clutch Piston And Seal Assembly
Courtesy of FORD MOTOR CO.

NOTE: Prior to installing the coast clutch piston lubricate the piston seal with petroleum jelly.

Fig 3: Installing Coast Clutch Piston

Courtesy of FORD MOTOR CO.

Using the special tool, install the coast clutch piston.
Using the special tool, install the coast clutch retaining ring.
1. Install the return spring.
2. Install the retaining ring.
  
  Fig 4: Installing Coast Clutch Retaining Ring
  Courtesy of FORD MOTOR CO.
Make sure that the one-way clutch is locked in place. Turn counterclockwise to lock in place.
Install the overdrive one way clutch.

Fig 5: Installing Overdrive One Way Clutch
Courtesy of FORD MOTOR CO.
Install the coast clutch pressure plate and the clutch plates.

Fig 6: Installing Coast Clutch Pressure Plate And Clutch Plates
Courtesy of FORD MOTOR CO.
Install the retaining ring.

Fig 7: Installing Retaining Ring
Courtesy of FORD MOTOR CO.
Check the stack-up clearance.
1. Using a feeler gauge, measure the stack up clearance in three 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: Checking Stack-Up Clearance
    Courtesy of FORD MOTOR CO.