Coast Clutch Assembly

Coast Clutch Assembly





Disassembly

1. Remove the No. 5 thrust bearing.





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





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





4. Remove the retaining ring.





5. Remove the coast clutch pressure plate One-Way Clutch (OWC) (mechanical diode) assembly and the clutch plates.





6. Using the Clutch Spring Compressor Aligner and Clutch Spring Compressor, remove the coast clutch return spring retaining ring.





7. Remove the coast clutch return spring.





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





9. 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.





10. 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.





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

Inspect the OWC inner race.

12. Remove and discard the retaining bolts for the coast clutch hub. Separate the 2 halves.





13. 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 Clutch Piston Seal Protector, install the coast clutch piston.





3. Install the coast clutch return spring.





4. Using the Clutch Spring Compressor Aligner and Clutch Spring Compressor, 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 is found or if 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 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.









7. Install the retaining ring.





8. 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.





9. 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.





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.