Overdrive Brake and Coast Clutch Drum Assembly: Material

• Inspect the drum band surface, bushing, and thrust surfaces for damage.
• Inspect the clutch piston bore, and piston.
• Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
• Inspect the clutch plates for damage.
• Inspect the clutch springs.

1. Disassemble the parts in the order indicated in the following illustration and table. See Fig 1.
   Fig 1: Identifying Removal Sequence Of Overdrive Brake And Coast Clutch Drum Assembly Components

   Courtesy of FORD MOTOR CO.
2. To assemble, reverse the disassembly procedure.

Item 5: Retaining Ring Disassembly Note 

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 2: Removing Coast Clutch Piston Retaining Ring
Courtesy of FORD MOTOR CO.
1. Using the special tool, remove the coast clutch piston retaining ring.

Item 8: Direct and Overdrive Clutch Piston Disassembly Note 

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. Failure to follow these instructions may result in personal injury.
Fig 3: Removing Coast Clutch Piston
Courtesy of FORD MOTOR CO.
1. 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.

Item 11: Overdrive Brake and Coast Clutch Drum Assembly Note 

1. Verify the check ball is free to move.
   Fig 4: Verifying Free Movement Of Check Ball

   Courtesy of FORD MOTOR CO.

Items 9 and 10: Direct and Overdrive Piston Inner and Outer Seal Ring Assembly Note 

CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
Fig 5: Installing New Coast Clutch Piston Inner And Outer Seal
Courtesy of FORD MOTOR CO.
1. Install the new coast clutch piston inner and outer seal.

Item 8: Direct and Overdrive Clutch Piston Assembly Note 

CAUTION: Care must be taken to prevent damage to the seals during installation.
Fig 6: Installing Coast Clutch Piston
Courtesy of FORD MOTOR CO.
1. Lubricate the seals, then, using the special tool, install the coast clutch piston.

Item 5: Retaining Ring Assembly Note 

CAUTION: Do not fully compress the special tool or damage to the coast clutch piston spring retainer may occur.
Fig 7: Installing Coast Clutch Piston Spring Retainer Ring
Courtesy of FORD MOTOR CO.
1. Using the special tool, install the coast clutch piston spring retainer ring.

Items 3 and 4: Coast Clutch External Steel Plate and Internal Friction Plate Assembly Note 

CAUTION: Coast clutch friction plates are directional and must be installed with grooves clockwise (I.D. to O.D.). 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 8: Installing Coast Clutch Disc Pack
Courtesy of FORD MOTOR CO.
1. When installing friction plates, the word "TOP" should face up. If reusing plates, grooves must be installed clockwise. Install the coast clutch disc pack.
2. Install the two steel clutch plates and two friction clutch plates in an alternating order, starting with a steel clutch plate.
   Fig 9: Installing Steel Clutch Plates And Friction Clutch Plates

   Courtesy of FORD MOTOR CO.

Item 1: Retaining Ring Assembly Note 

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. Failure to follow these instructions may result in personal injury.
Fig 10: Checking Correct Seating Of Piston
Courtesy of FORD MOTOR CO.
1. Air check the assembly.
   • Apply air pressure to the hole in the drum while blocking the other hole with a finger to make sure a correct piston seal has been established.
2. 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 DISC PACK FREE PLAY SPECIFICATION
      
      

      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 11: Checking Clearance Between Coast Clutch Retaining Ring And Coast Pressure Plate

   Courtesy of FORD MOTOR CO.