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, a new coast clutch cylinder must be installed.

Fig 1: Locating Ring Gear
Courtesy of FORD MOTOR CO.
Remove the No. 5 thrust bearing.

Fig 2: Removing Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the retaining ring and remove the center shaft.

Fig 3: Removing Retaining Ring And Center Shaft
Courtesy of FORD MOTOR CO.
Remove the overdrive planetary No. 4 thrust bearing.

Fig 4: Removing Overdrive Planetary Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the retaining ring.

Fig 5: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the coast clutch pressure plate one-way clutch (OWC) (mechanical diode) assembly and the clutch plates.

Fig 6: Removing Coast Clutch Pressure Plate One-Way Clutch
Courtesy of FORD MOTOR CO.
Using the special tool, remove the coast clutch return spring retaining ring.

Fig 7: Removing Coast Clutch Return Spring Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the coast clutch return spring.

Fig 8: Removing Coast Clutch Return Spring
Courtesy of FORD MOTOR CO.
Remove and discard the coast clutch piston and seal assembly.

Fig 9: 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.

Fig 10: Locating Sun Gear Teeth

Courtesy of FORD MOTOR CO.

If required, use an arbor press to remove the sun gear.

NOTE: If the coast clutch cylinder assembly shows any signs of damage, install a new coast clutch cylinder.

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 11: Inspecting Coast Clutch Cylinder Assembly
  Courtesy of FORD MOTOR CO.

NOTE: If the coast clutch hub shows any signs of damage, install a new coast clutch hub.

Inspect the one-way clutch inner race.
1. Vehicles equipped with a power take off (PTO), inspect the coast clutch hub bearing. Vehicles without a PTO, inspect the coast clutch hub bushing.
2. Inspect the power take-off ring gear teeth for damage.
3. Inspect the input shaft splines in the overdrive carrier.
  
  Fig 12: Illustration Steps-1, 2, And 3
  Courtesy of FORD MOTOR CO.
Remove and discard the retaining bolts for the coast clutch hub. Separate the two halves.

Fig 13: Removing Retaining Bolts For Coast Clutch Hub
Courtesy of FORD MOTOR CO.
Inspect the planet gears for damage. If any damage is found, install a new overdrive planet.

Fig 14: Locating Planet Gears
Courtesy of FORD MOTOR CO.