Cast Iron - Without Power Take-Off

Special Tools:

Part 1 Of 2:

Part 2 Of 2:

Disassembly





1. CAUTION: The coast clutch assembly is model dependent. The use of the wrong coast clutch assembly will result in a transmission failure.

Remove the overdrive sun gear.





2. Remove the coast clutch pressure plate retainer ring.





3. NOTE: Tag the parts for identification during installation.

Remove the (A) coast clutch pressure plate and the (B) clutch plates.





4. CAUTION: Do not fully compress the return springs or damage to return spring may occur.

Using the (A) Clutch Spring Compressor, compress the (B) coast clutch piston return spring and remove the (C) coast clutch piston return spring retaining ring. Remove the tool. Discard the retaining ring.





5. Remove the coast clutch piston return spring.





6. Remove the coast clutch piston apply ring.





7. Remove the coast clutch piston.





8. Remove the coast clutch piston outer seal.





9. Remove the coast clutch piston inner seal.

Assembly

NOTE: Soak all friction clutch plates for 15 minutes in clean Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent.

NOTE: Prior to installation, lightly lubricate all O-ring seals with clean Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent.





1. NOTE: Make sure the seal lip faces the coast clutch cylinder.

Install the coast clutch piston inner seal.





2. NOTE: Make sure the seal lip faces the coast clutch piston.

Install the coast clutch piston outer seal.





3. Install the coast clutch piston.





4. Install the coast clutch piston apply ring.





5. Install the coast clutch piston return spring.





6. CAUTION: Do not fully compress the return springs or damage to return spring may occur.

Using the (A) Clutch Spring Compressor, compress the (B) coast clutch piston return spring and install the new (C) coast clutch piston return spring retaining ring. Remove the tool.





7. Alternately install the (A) steel and the (B) friction clutch plates, beginning with a steel plate and ending with the (C) coast clutch pressure plate.





8. Install the selective coast clutch pressure plate retainer ring.





9. Check the stack-up clearance.
1 Using a feeler gauge, check the stack-up clearance in three places, 120 degrees apart.
2 If the clearance is not to specification, install the correct coast clutch pressure plate retainer snap ring and recheck the clearance. Refer to the Clutch Plate Usage and Clearance Specification Chart portion for selective snap ring thicknesses and part numbers.





10. Install the overdrive sun gear, with the short end of the gear downward.