Coast Clutch Assembly: Assembly

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Inspect the new coast clutch piston and seal assembly for damage and the check ball for free movement.

Fig 1: Coast Clutch Piston And Seal Assembly

Courtesy of FORD MOTOR CO.

Using the special tool, install the coast clutch piston.

Fig 2: Special Tool And Coast Clutch Piston

Courtesy of FORD MOTOR CO.

Install the coast clutch return spring.

Fig 3: Locating Coast Clutch Return Spring

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Using the special tool, install the coast clutch return spring retaining ring.

Fig 4: Coast Clutch Return Spring Retaining Ring

Courtesy of FORD MOTOR CO.

NOTE: The OWC mechanical diode is also the coast clutch pressure plate.

NOTE: Gas applications use a unique mechanical diode from diesel applications.

Inspect the OWC for cracks and damaged splines. When installed correctly, the internal splined portion of the OWC should rotate counterclockwise and lock when rotated clockwise. If any damage is found or if it does not rotate in the correct direction, install a new OWC.

Fig 5: Checking One-Way Clutch Operation

Courtesy of FORD MOTOR CO.

NOTE: Inspect all separator and friction plates for damage. If any damage is found to any of the plates, install new friction and separator plates.

NOTE: When installing the OWC (mechanical diode), the words THIS SIDE UP should be visible.

Install the coast clutch pressure plate OWC (mechanical diode) assembly and the clutch plates starting with the separator plate.

Item	Part Number	Description
1	7B442	Steel clutch plates (externally splined)
2	7B164	Friction clutch plates (internally splined)
3	7A089	Mechanical diode (OWC)

Fig 6: Coast Clutch Pressure Plates, Clutch Plates And Mechanical Diode (OWC)

Courtesy of FORD MOTOR CO.

Install the retaining ring.

Fig 7: Locating Retaining Ring

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Check the stack-up clearance.
- Using a feeler gauge, measure the stack-up clearance in 3 places, 120 degrees apart, between the snap ring and the coast clutch pressure plate.
- If the clearance is not within specification, install the correct coast clutch pressure plate retainer snap ring and recheck the clearance.

Fig 8: Checking Coast Clutch Pressure Plate Clearance With Specifications

Courtesy of FORD MOTOR CO.

Assemble the overdrive planet to the coast clutch hub. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 9: Overdrive Planet And Coast Clutch Hub Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Install the coast clutch hub assembly into the coast clutch cylinder assembly.
Install the No. 4 thrust bearing and washer.

Fig 10: Identifying Overdrive Planetary No. 4 Thrust Bearing

Courtesy of FORD MOTOR CO.

NOTE: When installing the retaining ring, make sure that it is completely seated in the groove with the tips down against the hub.

Install the overdrive ring gear to the center shaft and install the retaining ring.

Fig 11: Installing Overdrive Ring Gear To Center Shaft With Retaining Ring

Courtesy of FORD MOTOR CO.

Install the No. 5 thrust bearing.

Fig 12: Locating No. 5 Thrust Bearing

Courtesy of FORD MOTOR CO.