Clutch Trouble Shooting
Contents
1. 0 531 Inch 13 5 mm TARGET Clearance Between Release Bearing and 0 687 Inch 17 5 mm Clearance Between Tips of Release Fork 0 125 Inch 3 17 mm MINIMUM and Pads on Release Bearing 0 150 Inch 3 81 mm MAXIMUM 0 125 Inch 3 17 mm TARGET Clutch Pedal Free Travel Varies O 1 125 2 375 Inch 28 5 60 3 on floor NOTES See the specifications of the manufacturer of the vehicle Free travel specifications vary with the vehicle manufacturer O A 0 010 inch 0 254 mm feeler gauge must fit snugly between the release bearing and the clutch brake when the clutch pedal is fully depressed Lubricant Specifications Component Lubricant Interval Release Bearing High Temperature Multi Purpose Use the interval specified by Wheel Bearing Grease Meritor manufacturer of the vehicle Specification O 661 Lithium or the fleet but make sure the Complex Grease NLGI Grade 3 release bearing is lubricated once per month Use the interval specified by manufacturer of the vehicle or the fleet Cross Shaft Bushings In Clutch Housing Use the lubricant specified by the manufacturer of the vehicle Use the lubricant specified by the manufacturer of the vehicle Use the interval specified by manufacturer of the vehicle or the fleet Clutch Linkage Specifications Clutch Inspection Check List Transmission and Bell P Housing amp Clut2. E OK j not at specified dimension adjust RENNEN pins are not worn or damaged ipta bearing clearance Flat sides of pins are at a 90 angle to top of flywheel housing If not reinstall or replace pin Center plate to drive pin clearance is at least 0 006 inch 0 152 mm If not reinstall or replace pin lywheel and Flywheel Measured Clearance Release Fork to Release Bearing Clearance Release fork to release bearing linares is 0 125 inch 3 17 mm ue not at specified dimension adjust linkage See the procedure of the manufacturer of the vehicle For flywheel service information see the procedure of the manufacturer of the vehicle or the Pedal Height Sean See vehicle manufacturer specifications To adjust see the procedure of the manufacturer of the vehicle Measured Pedal Height Runout of the outer surface of the flywheel is 14 Inch Clutches 0 007 Inch 0 177 mm or less 15 1 2 Inch Clutches 0 008 Inch 0 196 mm or less Measured Runout Total Pedal Travel Specifications See the specifications of the manu facturer of the vehicle To adjust see the procedure of the manufac turer of the vehicle Runout of the bore of the pilot bearing is 0 005 inch 0 127 mm or less Measured Runout Measured Total Pedal Travel Clutch Brake Squeeze Non Syn chronized Transmission Release
3. Pressure plate is not cracked Heat marks can be removed with eme cloth Replace plate if marks cannot be removed Scratches are less than 0 060 inch 1 52 mm deep Pressure plate flatness is 0 000 0 005 inch 0 000 0 127 mm Measured Flatness 14 Inch Clutches with Organic Facings 0 610 Inch 15 5 mm a A Y O 15 1 2 Inch Clutches All 0 681 Inch 17 3 mm Measured Thickness Center Plate Flatness is 0 005 inch 0 127 mm or less new If flatness is more than 0 005 inch 0 0127 mm grind a new surface on the plate With new surface plate must be at or above minimum thickness Measured Flatness Center Plate Runout is 0 005 inch 0 127 mm or less If runout is more than 0 005 inch 0 127 mm grind a new surface on the plate With new surface plate must be at or above minimum thickness Measured Runout Piorsearng OR Pilot bearing is not worn or damaged Replace pilot bearing every time Pressure plate runout is 0 002 inch 0 05 mm or less Measured Runout Hub is not damaged Coaxial springs dampened discs only do not have any axial movement Oil or grease is not on discs Facings are not damaged or loose clutch is removed with a bearing that uses a high temperature rubber seal and grease 73 74 Specifications Clutch Inspection Check List Cont d Drive Pins amp Release Bearing Clearance 14 Inch Clutches Onl en OR Cont d ox
4. bearing housing must touch clutch brake when clutch pedal is typically 1 0 inch 25 mm from end of pedal travel For specifications see the specifications of the manufacturer of the vehicle To adjust see the procedure of the manufacturer of the vehicle Runout of the outer surface of the flywheel housing is 0 008 inch 0 203 mm or less Measured Runout Runout of the bore of the flywheel Housing is 0 008 inch 0 203 mm or less Measured Runout Measured Clutch Brake Squeeze Non Synchronized Transmissions Free travel varies from 1 125 to ste hoja ol an ae n 2 375 inches 28 60 mm To adjust housing and clutch brake see the procedure and specifications of the manufacturer of the vehicle Snychronized Transmissions between 0 687 inch 17 44 mm Measured Free Travel Measure release bearing housing and clutch cover Specifications INSTALLATION AND LUBRICATION INSTRUCTIONS Spicer Pull Type Clutches INSTALLATION INSTRUCTIONS 1 A new pilot bearing should be used when replacing a Clutch If the old bearing is reused clean and check the bearing thoroughly Repack with lubri cant Check condition of the flywheel If it is cracked or warped refer to the manufacturers recommenda tions concerning replacement or regrinding Check condition of transmission drive gear spline Use hand stone if necessary to dull the sharp edges of splines If splines are worn excessivel
5. tightening mounting bolts The spacer ring amp intermediate plate assembly Solos and SAS 1402 only was bolted up backwards onto the flywheel see Figures 34 37 If the clutch cover has already been bolted to the fly wheel it is imperative that it be replaced with a new intermediate plate assembly because permanent damage may have occurred to the drive straps and spacer ring Also thoroughly inspect the cover for any damage and replace if damaged The intermediate and or pressure plate is either cracked or broken see Figures 13 14 and 25 Replace any damaged parts This failure is caused by driver abuse or excessive heat as indicated by the following Holding vehicle on hill with the clutch Overload Starting off in the wrong gear Wrong cover assembly installed allowing clutch to slip misapplication Intermediate plate hanging up allowing clutch to slip Troubleshooting Poor Release Complaint Possible Causes Corrective Action Poor Release Release sleeve bushing is contacting the transmis Check for protruding cross shafts Continued sion input shaft due to a side loading condition This Install a new release yoke condition can be the result of one or more of the fol lowing items Cross shafts protruding through the release yoke Finger s of release yoke are bent Clutch cover is not mounted concentric and or not properly seated into the flywheel pil
6. FOR FREE PEDAL dimension h This 1 8 will provide approximately 1 1 2 free travel at the pedal Be sure to Eghten all locknuts NOTE Hydraulic linkage Refer to manufacturer s specifications for Proper adjustment of system and free pedal settings STEP 4 Verity dimensions or clutch brake settings Fig 2 and 3 For vehicies with Synchronized transmissions vehicles without dutch braka Release bearing must move between 1 77 and 4 16 tul pedal stroke to avoid clutch drag Semen a tomes riel 5 p occur 1 from the end of pedal stroke ee Depress the clutch pedal The pedal shouid be 1 2 to 1 from the end of stroke at the beginning of the dutch brake squeeze See 3 A To check this insert a 010 tesier gauge or business card between the release bearing and clutch brake refer to Fig 1 Depress the chrich pedal and squeeze the card Lat the pedal Up slowly Stop when the card can be pulled out The pedal Should be 1 27 to 1 trom the end of stroke mas 77 83 84
7. assure adequate distribution of the grease throughout the bearing engine should be running while grease is being added 75 Specifications ADJUSTING PROCEDURE Spicer Angle Spring Clutches Before adjusting anything suppose we review the conditions required for proper clutch action A pull type clutch permits use of a simple clutch brake The brake squeeze should begin about 1 inch from the floor board or the end of pedal stroke Any clutch will slip and burn up if there is no free pedal To release property the clutch release bearing must move about 1 2 inch This occurs between the end of free pedal travel and the brake actuation point 76 For Both Manual amp Self Adjusting Clutches Set Clutch Linkage to begin brake squeeze 1 above floor board or end Proper adjustment of clutch brake is achieved hy sharten ing or lengthening the exter nal linkage rod NOTE Hydraulic linkage Refer to manufacturer s specifications for proper adjustment of system Synchronized Transmissions No Brake Adjust external linkage so release bearing almost contacts transmission bearing cap when pedal is fully depressed Verify 2 release travel For Both Manual amp Self Adjusting Clutches Ciutch Brake Visually check both free travel and release travel shown below Froe Travel x 14 Diameter Single Plate 1 873 010 For Manual Adjusting STEP Clutches Only Adjust
8. to approx imately 11 2 free pedal Pedal must be held down to move adjusting ring Remove adjusting lockstrap Turning the adjusting ring clockwise moves the release bearing toward the transmission Increases Free Pedal Turning adjusting ring counter clockwise moves the release bearing toward the engine Decreases Free Pedal For Manual Adjusting BIER Clutches Only Fiywheel Depth STEP For Self Adjusting Clutches Only Bon A Remove right bolt A Loosen left bolt one turn A B Rotate adjuster up ward This will worm gear from the adjust ing ring to allow manual adjustment Hold adjuster disengaged and tighten left bolt C Rotate adjusting ring until approximately 11 2 of free pedal is acquired pedal must be down Rotate clockwise to increase free pedal counter clockwise to decrease D Loosen left hand bolt rotate adjuster assembly downward to engage worm with adjusting ring teeth Adjusting ring may have to be rotated slightly to allow worm to mesh E Install right bolt and tighten both bolts 30 35 Ibs ft torque For Self Adjusting Clutches Only STEP Visual y check to see if actuator arm a is in serted into release sieeve re tainer b If ad justing assembly is installed prop erly the adjuster assembly spring will move back and forth as pedal is stroked NOTE The clutch will nct self adjust if the actuator arm is not inserted into the rel
9. 62 Troubleshooting Pull Type Clutches Poor Release Complaint Possible Causes Corrective Action Poor Release Intermediate plate sticking on drive lugs due to cocked drive pins AS and EP 1402 only see Figures 18 19 Drive pins must be 90 square to the flywheel surface with 006 minimum clearance between drive pins and intermediate plate slots Pressure plate not fully retracting Check pressure plate return springs to see if bent stretched or broken These springs can be replaced through the inspection opening Transmission re moval is not necessary Verify that the release bearing travel is 1 2 9 16 Determine if the lever nose is out of the groove in the release sleeve retainer If it is be sure to reinstall Excessive release bearing travel causing lever to con tact pressure plate in excess of 5 8 Adjust to 1 2 9 16 release bearing travel Incorrect pedal height Set the pedal height so you can obtain 1 2 to 9 16 release bearing travel 1 8 free travel at the release yoke and 1 2 to 1 clutch brake squeeze Consult the truck service manual or Eaton s Installa tion Instructions No clutch brake squeeze 1 2 1 required Damaged bushing in the release bearing sleeve as sembly Replace cover Cover assembly not properly seated into pilot of fly wheel Reseat into flywheel Use crisscross pattern when
10. ITHOUT CLUTCH BRAKE FOR BOTH MANUAL AND SELF ADJUSTING CLUTCHES B FOR BOTH MANUAL amp SELF ADJUSTING CLUTCHES WITH CLUTCH BRAKE greater than 9 16 adjust clutch as Outlined in following steps FIG 1 1 RELEASE THE CLUTCH BY DEPRESSING THE CLUTCH PEDAL TO THE END OF PEDAL TRAVEL 2 ADJUST THE CLUTCH INTERNALLY TO GET 1 2 TO 9 16 RELEASE THIS IS DONE BY TURNING THE ADJUSTING RING 1 f clearance between release bearing housing and dutch brake is losa than 1 27 rotate the adjusting ring counterclockwise which moves the release bearing toward the engine 2 If clearance between the release bearing housing and clutch brake is greater than 9 16 rotate the adjusting ring clockwise which moves the release bearing toward the transmission 3 REINSTALL LOCKSTRAP FOR MANUAL ADJUSTED CLUTCHES ONLY ar 38 40 be torque N H Pains the loca KWIK ADJUST Assure Kwk Adjust is rotated to ks locked position with the boit fats agred with braci REPOSITION WEAR COMPENSATOR ASSEMBLY FOR WEAR COMPENSATOR CLUTCHES ONLY A Loosen left hand boit rotate assembly F downward to engage worn with mney have tb rotated er E mue may lo be rotated slightly to allow compensator assembly spring will move beck and forth es pedal is fully stroked NOTE The chitch will not compensate for wear the actuator arm is not inserted Into the release sleeve retainer or release Dearing travel is less than 1 2 STEP3 LINKAGE ADJUSTMENT
11. ating procedures are used Linkage touches other components Route or repair linkage as required No Free Travel Damaged clutch linkage Repair linkage Clutch and or linkage Adjust release bearing clearance and out of adjustment clutch linkage Clutch not installed correctly Install clutch correctly Scrape Clutch linkage not lubricated Lubricate linkage at specified intervals with correct lubricant Damaged linkage Repair linkage Linkage touches other components Route or repair linkage as required Squeak Clutch linkage not lubricated Lubricate linkage at specified intervals with correct lubricant Damaged linkage Repair linkage Linkage touches other components Route or repair linkage as required 69 70 Specifications Pressure Plate Specifications Description 14 Inch Clutches 15 1 2 Inch Clutches Pressure Plate Parallelism 0 000 0 005 inch 0 000 0 005 inch New 0 000 0 127 mm 0 000 0 127 mm Pressure Plate Flatness 0 000 0 005 inch 0 000 0 005 inch New 0 000 0 127 mm 0 000 0 127 mm Maximum Allowable Wear 0 060 inch 1 52 mm 0 060 inch 1 52 mm Center Plate Specifications Description 14InchClutches 15 1 2 Inch Clutches Center Plate Parallelism 0 000 0 005 inch 0 000 0 005 inch Center Plate Flatness 0 000 0 005 inch 0 000 0 005 inch Center Plate Minimum Thickness 0 728 inch 18 5 mm 0 681 inch 17 3 mm Ceramic Linings 0 610 inch 15 5
12. ch Discs Cont d Bell housing is not worn or damaged Fase Sven ratove motes Facing wear is even or above the top of the rivet Unused cross shaft bores in bell Inspection cover is installed Molded Organic Facing Facing housing are plugged thickness is 0 283 inch 7 2 mm or less Center Plate 14 Inch Clutches Slots in plate are not damaged If every other slot is damaged install good slots over drive pins If all slots are damaged replace plate 15 1 2 Inch Clutches Tab to slot clearance is at least 0 006 inch 0 152 mm If not index to get correct clearance or replace plate Tabs on plate are not damaged Thickness Plates are at or above specified thickness 14 Inch Clutches with Ceramic Facings 0 728 Inch 18 5 mm Input bearing retainer is not worn or damaged CILA ER ER ER ER TUTE TT HE EN Distance between top of input shaft and top of input bearing retainer is 0 00 8 72 inches 000 00 221 48 m Release fork is straight Fork tips are not worn or damaged Cross shaft moves freely Radial or side to side movement of the cross shaft is not excessive The cross shaft and bushings if used are not worn or damaged Input shaft splines are not worn or damaged Clutch brake contact area non synchronized transmission only on input bearing retainer is not worn or damag Pressure Plate and Cover Assembly Cover is not broken Diaphragm spring is not damaged
13. ease sleeve retainer or release bearing travel is less than Ye 15 2 Diameter Double Plate 2 938 010 Double Plate 150 180 Specifications ADJUSTING PROCEDURE Spicer Type Angle Spring Pull Type Clutches UNDERSTANDING SPICER CLUTCH ADJUSTMENT To assure optimum performance of Spicer Clutches a 1 2 to 9 16 release travel is required b 1 8 tree travel clearance between release bearing and release yoke TERMINOLOGY 1 RELEASE TRAVEL 1 2 to 9 16 Proper release travel assures that the relanse bearing is capable of traveling far enough allowing the driven disc s to spin Ireely avoiding clutch drag 2 CLUTCH FREE PEDAL Pedal tree play is an indication of clutch adjustment interval When tree pedal la no longer present begin adjustment procedures as outlined below 3 CLUTCH FREE TRAVEL 1 8 ADJUSTMENT NORMAL he C ch component wear is adjusted Internally in the chich through clockwise rotation of the adjusting ring This adjustment moves the release bearing toward the transmission fe estabishes the 1 2 release travel and 1 8 tree travel 2 LINKAGE and throw 8 To compensate for linkage wear or replacement ol related clutch or linkage components NOTE Adjustments are pertormed with pedal depressed dutch released adjustment mechanisms for the Stamped They are shown as follows There are three versions of Anglo Spring Clutches STEP 2 A CLUTCH ADJUSTMENT W
14. een the release yoke fingers and the release bearing wear pads travel Misapplication of clutch causing premature wear If a service clutch determine whether the clutch is properly specified for the vehicle s particular applica tion Starting out in too high a gear may lead to premature clutch wear Start the vehicle in the proper gear Refer to item 1 of Factors That Effect Clutch Performance Worn cross shafts and or linkage system Investigate entire linkage system to determine if it is binding or operating sporadically and or worn exces sively Clutch discs wore down to rivets Install new clutch Riding of clutch pedal causing premature wear Refrain from using the clutch pedal as a foot rest Troubleshooting Vibrating Clutch Complaint Possible Cause Corrective Action Holding the vehicle on an incline by using the slipping clutch as a brake Doing this can cause premature wear Refrain from using the clutch pedal as a brake Sporadic changes in the amount of free play free trav el due to excessive crankshaft end play Consult the engine OEM Service Manual Too much Free Play on Solo Clutch Complaint Possible Cause Corrective Action Too much Free Play on Solo Clutch Failure to install a clutch brake when one is required This condition will cause the Solo s release bearing to adjust closer than normal to the transmiss
15. he intermediate plate The release yoke bridge is contacting the cover as sembly at the full release position clutch pedal to floor see Figures 1 2 It is highly recommended that the 6 six items listed next to Figures 1 and 2 be thoroughly investigated be fore installing a new clutch Damaged or non functioning clutch brake see Fig ures 73 74 Install new clutch brake when installing a new clutch and or replace existing brake with 2 piece Kwik Kon nect type Rust preventative i e never seize grease etc on transmission input drive gear See Figures 43 45 Drive gear should be clean and dry before installing discs Incorrect use of clutch brake when shifting into 1st gear Sometimes when applying the clutch brake with the vehicle on a grade the transmission gears can be come locked together due to the applied torque mak ing it difficult to shift into and out of gear Let up on the clutch pedal a few inches in order to dis engage the clutch brake Doing so will allow the input shaft to roll over slightly eliminating the locking con dition of the transmission gears and allow for effort less shifting Facing of driven disc assemblies are coated with oil or grease see Figures 41 43 44 Replace the driven disc assemblies Cleaning of old discs is not recommended Foreign material on the internal workings of the clutch cover dirt chaff salt etc Remove foreign materia
16. ion s bear ing retainer cap and will also cause the wear tab to move toward the half worn position Reset the wear tab to the new position Install a 2 piece Eaton Fuller Clutch Brake Readjust the Solo us ing the normal adjusting procedures Solo Clutch has over adjusted release bearing is less than 500 standard stroke Solo or 430 short stroke from the transmission Reset the wear tab to the new position Readjust the Solo using the normal adjusting procedures Failure to properly set up the clutch linkage Reset the linkage to obtain a free travel at the yoke range of 1 16 1 8 Nothing is wrong It is normal for the free play to in crease during the Solo s Breaking in period None is required but if the additional free play is ob jectionable you may readjust the linkage until you have 1 16 1 8 of free travel at the release yoke Clutch Slippage Complaint Possible Cause Corrective Action Clutch Slippage No free pedal Readjust clutch Refer to adjustment instructions found in Eaton s Installation Instructions Release mechanism binding Free up mechanism and linkage check clutch adjust ment Refer to adjustment instructions found in Eaton s Installation Instructions Failure to remove shipping resetting bolts Solo HD amp MD Remove shipping resetting bolts Grease or oil on facings see Figures 41 43 44 Replace dr
17. iveline angles Shim drivetrain components to equalize u joint an gles Flywheel is not balanced Balance the flywheel Pilot area of the clutch is not completely seated into flywheel Ensure that no dirt burrs etc are preventing the cov er from completely seating into the flywheel mounting surface Failure to tighten the clutch cover mounting bolts us ing a criss cross sequence can cause an out of bal ance condition Loose mounting bolts can also induce this condition Figures 8 10 Consult Eaton Clutch Service Manual Damaged loose or worn out engine mounts Replace any damaged worn parts Retighten all loose bolts to proper specifications Refer to the OEM en gine manufacturer s service manual Misfiring of engine Refer to OEM engine manufacturer s service manual Excessive flywheel runout Refer to Eaton s Installation Instructions Rivets of the rear disc are interfering with the retainer assembly see Figures 25 and 57 Adjust the clutch internally instead of externally Clutch is loose on flywheel see Figures 8 10 Install a new clutch assembly and eight new mount ing bolts Insufficient amount of free travel When the clutch was initially installed the linkage was not adjusted to obtain a full 1 8 free travel After first adjusting the clutch for I 2 9 16 release bearing travel adjust the linkage to obtain an 1 8 free travel distance betw
18. iven disc assembly Driver riding clutch pedal Refrain from riding clutch pedal Overloaded clutch Verify that the proper clutch has been specified for the vehicle s application 67 68 Troubleshooting Chattering Erratic Engagement Clutch Grabs truck is difficult to launch Complaint Possible Cause Corrective Action Chaffering Er Input shaft spline wear see Figure 77 Replace input shaft ratic Engage ment Clutch Grabs Clutch is worn out the driven disc assembly s have worn down to the facing rivets see Figure 70 Replace all worn components The linkage system is not operating freely it is bind ing and or worn excessively see fig 75 Replace all worn parts being sure to lubricate accord ing to the OEM Service Manual Grease oil on the disc s facing material see Figure 41 43 44 Replace disc s Loose engine mounts Retighten to OEM specs The fingers of the release yoke and or the wear pads on the release bearing are worn excessively see Fig ures 29 and 79 Replace all worn parts The electronic engine is not programmed properly re garding clutch engagement torque Consult with OEM engine manufacturer Push Type Clutches Poor Release Complaint Possible Cause Corrective Action Poor Release Insufficient amount of clutch pedal height may pre vent the throw out bearing from trave
19. l Ensure that the transmis sion inspection hole cover is reinstalled to minimize future problems Troubleshooting Noisy Rattling Complaint Possible Cause Corrective Action Noisy Rattling Excessive flywheel runout Corrosion of disc hubs to transmission input shaft Consult Eaton s Installation Instructions Clean the mating parts to ensure that the discs slide freely over input shaft Engine idling too fast Readjust engine to proper idling speed Clutch release bearing is dry or damaged see Figures 28 29 Lubricate the bearing If the noise persists install a new clutch cover the release bearing will be included with the cover Flywheel pilot bearing is dry or damaged see Figure 76 Replace flywheel pilot bearing Bridge of the yoke hitting clutch cover Refer to the section titled Failure yoke bridge rub bing into clutch cover Figures 1 2 Fingers of release yoke hitting clutch cover Refer to the section titled Failure yoke fingers rub bing into clutch cover Figures 4 5 Failure to use the transmission inspection hole cover Re install the cover Failure to use anti rattle springs AS and EP 1402 Su per Duty only see Figures 20 22 Always install the new anti rattle springs packaged with each 14 Super Duty clutch Worn sleeve bushing Investigate for any side loading conditions on the re lease bearing ho
20. ling far enough to disengage the clutch Consult the OEM Service Manual and or Eaton s In stallation Instructions Incorrect throw out bearing was installed A throw out bearing assembly that is too short cannot travel far enough to enable full disengagement of the clutch Install the correct throw out bearing Excessive free pedal in the cab the clutch cannot ful ly disengage Consult the OEM Service Manual Throw out bearing is hanging up on the quill stem of transmission Consult the OEM Service Manual Missing and or improper torquing of clutch cover mounting bolts Consult Eaton s Installation Instructions Incorrect driven assembly installed it is too thick Install the correct disc Noisy Rattling Complaint Possible Cause Corrective Action Noise Rattling Throw out bearing is worn seized Replace the throw out bearing If reusing the clutch ensure that the release levers are not damaged see Figure 38 Incorrect driven disc has been installed Install correct driven disc assembly Troubleshooting Pedal Operation Clutch linkage not lubricated Lubricate linkage at specified intervals with correct lubricant Damaged clutch linkage Repair linkage Clutch out of adjustment Adjust release bearing clearance and clutch linkage Damaged input shaft Replace input shaft Make sure correct installation and driver oper
21. mm Organic Linings Center Plate Driving Method Drive Pin in Tabs on Center Plate Flywheel Mate in Clutch Cover EEE Fr MIN Center Plate Tab to Cover Slot 0 006 inch 0 152 mm Clutch Brake Specifications Specification Free Play Spline Diameter 1 75 Inch 2 00 Inch Torque Limited 15 30 Ib ft 2 1 4 0 kg m Specifications Clutch Disc Specifications 14 Inch 15 1 2 Inch Description Clutches LTD Clutches Number of Splines IT EE O Spline Diameter 1 75 Inch 2 00 Inch 2 00 Inch 2 00 Inch Hub Type Number of Co Axial Spring Sets 8 CIA E Ceramic Pad Material Asbestos Free Asbestos Free Asbestos Free Ceramic and Ceramic and Ceramic and Metallic Material Metallic Material Metallic Material Organic Pad Material Asbestos Free Asbestos Free OganeMaterat Orgarie Materai Minimum Disc Thickness To Top of Rivet To Top of Rivet To Top of Rivet EHE pe Minimum Disc Thickness 0 283 inch 7 2 mm 0 283 inch 7 2 mm a Torque Specifications Lb Ft Nm Adjusting Ring Lock Capscrew 25 30 34 40 Strap to Cover Capscrew 29 43 40 58 Cover Assembly to Flywheel Capscrew 14 Inch Clutches Cover Assembly to Flywheel Capscrew 15 1 2 Inch Clutches 71 72 Specifications Clutch Adjustment Specifications Description Specification Clearance Between Release Bearing and 0 500 Inch 12 7 mm MINIMUM Clutch Brake Non Synchronized Transmission 0 562 Inch 14 2 mm MAXIMUM
22. op If Cross Shaft is below center rotate Bearing Housing 180 Rotate Clutch Release Yoke so that release yoke fin gers clear the pads on the Release Bearing Housing 14 15 16 Use a Sling or transmission jack to support and maintain the engine to transmission alignment while installing the transmission Use care to avoid hanging the weight of the transmission on the clutch or forcing the transmission into the clutch or flywheel housing Either of these abuses can cause bent or sprung Driven Discs and prevent the clutch from releasing Rotate Clutch Release Yoke into proper position as transmission is moved into place Start all transmission bell housing cap screws and tighten progressively around the housing to torque recommended by vehicle manufacturer Connect clutch release linkage and check release bearing travel clutch brake squeeze and proper free pedal Adjust as necessary PROPER POSITION OF FRONT AND REAR DRIVEN DISCS IN INSTALLATION See below DAMPER CONSTRUCTION SHOWN ABOVE CENTER LINE FLYWHEEL FLYWHEEL SURFACE SURFACE RIGID CONSTRUCTION SHOWN BELOW CENTER LINE LUBRICATION INSTRUCTIONS 4 WARNING The release bearing housing has been pre packed with grease Only high temperature greases should be used Chassis lube or all purpose lubricants are not recom mended Add lubricant at each chassis lubrication period or more often if service is extreme To
23. or proper fit Damaged or dry rough pilot bearing see Figure 76 Replace with new bearing Failure to use the anti rattle springs packaged with all 14 AS and EP Super Duty clutches see Figures 20 22 Always use new anti rattle springs 3 Anti rattle springs were installed backwards see Figures 23 24 Install them so the rounded sections are pointing to ward the flywheel engine Failure to set the positive separator pins during clutch installation It is important to note that the procedure for setting the positive separator pins model 1552 Solo amp SAS 1402 clutches can be performed while the transmis sion is installed The steps are as follows 1 Remove the transmission inspection hole cover 2 Rotate the clutch cover until one of the holes for setting the pins is at the 6 o clock position 3 Using the appropriate tool lightly tap the separator pin to verify that it is seated against the flywheel 4 Repeat steps 2 and 3 for the remaining three sepa rator pins 5 Reinstall the transmission inspection hole cover For additional information refer to Eaton s Installa tion Instructions 63 64 Troubleshooting Poor Release Complaint Possible Causes Corrective Action Poor Release Bent damaged positive separator pin s see Figures 1 Be sure to use the proper tool when setting the Continued 31 33 pins 2 Take great care when handling t
24. ot Misalignment between the transmission bell hous ing and engine housing Loose transmission mounting bolts Improper setup of linkage When mounting clutch cover to the flywheel al ways tighten the mounting bolts to their proper torque using the crisscross pattern Refer to Eaton s Installation Instructions on the proper techniques for checking misalignment Tighten bolts to proper torque Thoroughly examine the linkage to determine if it can be contributing to a side loading condition Driven disc distorted or warped see Figure 47 Damage to driven discs can be caused by poor instal lation methods Do not force transmission drive gear into disc hubs This will distort or bend driven disc causing poor release Also do not allow transmission to hang unsupported Replace any distorted or warped discs Disc s installed backwards see Figures 49 amp 50 or front and rear discs were switched with each other Install new discs Also investigate the clutch cover for any damage Replace if damaged Spline worn on main drive gear of transmission see Figure 77 Replace drive gear and check driven disc hubs for ex cessive wear If worn replace disc Check flywheel housing alignment of engine and transmission Make sure driven discs slide freely on drive gear splines Flywheel pilot bearing fits either too tight or too loose in the flywheel and or end of input shaft Check pilot bearing f
25. using Determine the cause being sure to correct before installing the new clutch Linkage system is frozen improperly lubricated worn excessively has missing parts washers etc or the linkage itself is rattling excessively Clean lubricate and reassemble or replace missing worn parts Idle gear rattle coming from the transmission Specify driven disc assemblies which feature Free Travel design Check the engine for the correct idle speed Consult the OEM engine manual Dampener spring cover of the driven disc assembly interfering with the flywheel Figures 48 52 Install correct clutch assembly Rivets of the rear disc are interfering with the retainer assembly see Figures 25 and 57 Adjust the clutch internally via the adjusting ring not externally via the linkage system Clutch is loose on flywheel see Figures 8 10 Install a new clutch assembly and eight new mount ing bolts 65 66 Troubleshooting Vibrating Clutch Complaint Possible Cause Corrective Action Vibrating Clutch Loose flywheel Retighten flywheel mounting bolts to the proper spec ifications Worn universal joints Replace worn parts Improper phasing of driveshaft Investigate for correct yoke phasing Driveshaft is not balanced Balance and straighten driveshaft Also ensure that no balance weights have come off the driveshaft Incorrect dr
26. y or notched Driven Discs will not slide and drive gear should be replaced Make sure Drive Pin heads are square with flywheel friction face Most vehicles use one or two set screws per Drive Pin to lock the Drive Pin in position These set screws must be loosened or removed to turn or to replace Drive Pins New drive pins should be installed anytime the clutch is replaced Worn or damaged drive pins can cause faulty clutch operation Use 6 drive pins with minimum of 006 clearance between Drive Pin and Intermediate Plate Slot at each location Some units use 4 drive pins only Install Front Driven Disc Intermediate Plate and Rear Driven Disc See illustration for proper posi tioning of driven discs Place cover assembly in position on flywheel and start cap screws Note Lockstrap must be aligned with access hole in bell housing Insert spline aligning tool through Clutch Assembly and into pilot or pocket bearing Progressively tighten cap screws which hold Cover Assembly to flywheel 35 to 40 Ibs ft of torque is recommended Bolt Tightening Sequence 35 40 Ft Lbs Remove the two wooden blocks from between the Release Bearing Housing and Flywheel Housing Remove spline aligning tool ff Clutch Brake is to be used place brake parts on the main drive gear of the transmission and shift transmission into gear Rotate Clutch Release Bearing Housing so that flat section is on t
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