Coast Clutch Assembly

Coast Clutch Assembly





Special Tool(s)

Disassembly





1. 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.





2. Remove the No. 5 thrust bearing.





3. Remove the retaining ring and remove the center shaft.





4. Remove the overdrive planetary No. 4 thrust bearing.





5. Remove the retaining ring.





6. Remove the coast clutch pressure plate one-way clutch (OWC) (mechanical diode) assembly and the clutch plates.





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





8. Remove the coast clutch return spring.





9. Remove and discard the coast clutch piston and seal assembly.





10. NOTE: If the teeth and or bushing are damaged, a new sun gear will need to be installed.

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





11. 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.





12. 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.





13. Remove and discard the retaining bolts for the coast clutch hub. Separate the two halves.





14. Inspect the planet gears for damage. If any damage is found, install a new overdrive planet.

Assembly





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





2. Using the special tool, install the coast clutch piston.





3. Install the coast clutch return spring.





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





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

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 found or it does not rotate in the correct direction, install a new OWC.








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

NOTE: When installing the one-way clutch (OWC) (mechanical diode) the words "this side up" should be visible.

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





7. Install the retaining ring.





8. Check the stack-up clearance.
^ Using a feeler gauge, measure the stack-up clearance in three 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.





9. Assemble the overdrive planet to the coast clutch hub. Tighten bolts in the sequence shown in two stages.
^ Stage 1: Tighten bolts to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten bolts an additional 90 degrees.
10. Install the coast clutch hub assembly into the coast clutch cylinder assembly.





11. Install the No. 4 thrust bearing and washer.





12. 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.





13. Install the No. 5 thrust bearing.