Coast Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Vehicles equipped with power take-off (PTO) will have a ring gear pressed over the coast clutch cylinder. Do not try to remove the ring gear. If the ring gear shows signs of damage, installation of a new coast clutch cylinder will be necessary.

Fig 1: Removing Ring Gear
Courtesy of FORD MOTOR CO.
Remove the retaining ring.

Fig 2: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the coast clutch pressure plate and the clutch plates.

Fig 3: Removing Coast Clutch Pressure Plate And Clutch Plates
Courtesy of FORD MOTOR CO.
Inspect the overdrive one-way clutch for damage to the plastic cage, springs, and rollers. Replace as necessary. Remove the overdrive one-way clutch.

Fig 4: Inspecting Overdrive One-Way Clutch
Courtesy of FORD MOTOR CO.
Using the special tool, remove the coast clutch return spring.
1. Remove the retaining ring.
2. Remove the return spring.
  
  Fig 5: Removing Coast Clutch Return Spring
  Courtesy of FORD MOTOR CO.
Remove the coast clutch piston and seal assembly.

Fig 6: Removing Coast Clutch Piston And Seal Assembly
Courtesy of FORD MOTOR CO.

NOTE: If the teeth and or bushing are damaged, a new sun gear will need to be installed.
If required, use an arbor press to remove the sun gear.

Fig 7: Removing Sun Gear
Courtesy of FORD MOTOR CO.

NOTE: If the shows any signs of damage, install a new coast clutch cylinder.
Inspect the coast clutch assembly.
1. Inspect the bushing.
2. Inspect the No. 1 thrust washer.
3. Inspect the lube hole.
  
  Fig 8: Inspecting Coast Clutch Assembly
  Courtesy of FORD MOTOR CO.
Inspect the one-way clutch inner race.
1. Inspect the coast clutch hub overdrive OWC inner race.
2. Inspect all the sealing surfaces.
3. Inspect the sun gear splines.
  
  Fig 9: Inspecting Coast Clutch Hub Overdrive OWC Inner Race
  Courtesy of FORD MOTOR CO.
For vehicles equipped with power take-off (PTO), inspect the bearing for damage. If the bearing is damaged, install a new coast clutch cylinder.

Fig 10: Installing A New Coast Clutch Cylinder
Courtesy of FORD MOTOR CO.

NOTE: If the coast clutch cylinder shows any signs of damage, install a new coast clutch cylinder.
For vehicles equipped with power take-off (PTO), inspect the one-way clutch inner race.
1. Inspect the coast clutch hub one-way clutch inner race.
2. Inspect the power take-off ring gear teeth for damage.
3. Inspect all sealing surfaces, and lube hole.
4. Inspect the sun gear splines.
  
  Fig 11: Inspecting Sun Gear Splines
  Courtesy of FORD MOTOR CO.