Coast Clutch Assembly: Disassembly

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, and 2003 Ford Excursion. 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: Identifying Ring Gear Pressed Over Coast Clutch Cylinder
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 & 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 Clutch Spring Compressor (307-015), remove the coast clutch return spring.
1. Remove the retaining ring.
2. Remove the return spring.
Fig 5: Removing Coast Clutch Retaining Ring & Return Spring
Courtesy of FORD MOTOR CO.
Remove the coast clutch piston and seal assembly.

Fig 6: Removing Coast Clutch Piston & 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 7: Removing Sun Gear

Courtesy of FORD MOTOR CO.

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

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

Fig 8: 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 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 One-Way Clutch 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: Inspecting One-Way Clutch Bearing (With PTO)
Courtesy of FORD MOTOR CO.

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

Fig 11: Inspecting One-Way Clutch Inner Race

Courtesy of FORD MOTOR CO.

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.