Coast Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the retaining ring.

Fig 1: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the coast clutch pressure plate and the clutch plates.

Fig 2: 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 3: Removing 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 4: Removing Coast Clutch Return Spring Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the coast clutch piston and seal assembly.

Fig 5: Removing Coast Clutch Piston And Seal Assembly
Courtesy of FORD MOTOR CO.

NOTE: If the teeth and/or bushing are damaged, the sun gear will need to be replaced.

Fig 6: Removing Sun Gear Using Arbor Press

Courtesy of FORD MOTOR CO.

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

NOTE: If the coast clutch cylinder shows any signs of damage it will need to be replaced.

Fig 7: Inspecting Coast Clutch Assembly

Courtesy of FORD MOTOR CO.

Inspect the coast clutch assembly.
1. Inspect the bushing.
2. Inspect the No. 1 thrust washer.
3. Inspect the lube hole.
Inspect the one-way clutch (OWC) 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 8: Inspecting One-Way Clutch Inner Race
Courtesy of FORD MOTOR CO.