Coast Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Vehicles equipped with power take-off 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: Identifying Ring Gear
Courtesy of FORD MOTOR CO.
Remove the No. 5 thrust bearing.

Fig 2: Removing No. 5 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 No. 4 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 Assembly
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: Removing Sun Gear

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: Installing Lube Hole
  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: Inspecting Input Shaft Splines In Overdrive Carrier
  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: Inspecting Planet Gears For Damage
Courtesy of FORD MOTOR CO.