"service manual"
Contents
1. Hydraulic Linkage Adjustment Transmission Installation Freeplay Non Synchronized Depending on the application freeplay can be achieved by adjusting upper pedal stop or by adjusting master cylinder pushrod 1 Freeplay 3 8 mm Clutch Brake Squeeze For non synchronized applications only 1 Clutch servo 2 To master cylinder 3 Connect air supply 30 psi source Bolts 4 M16 x 1 5 mm torque 20 25 Nem 4 Bolts 2 M8 x 1 25 mm torque 20 25 Nem 5 Pushrod Slave Cylinder 1 Clutch brake squeeze 13 50 mm 1 Slave cylinder 29 Hydraulic Linkage Synchronized Hose Assembly 1 Connect hose assembly to master cylinder and slave or booster Depending on hose type this is either a threaded connect or snap to connect Torque all connectors to 20 25 Nem Note Make sure there is a constant rise to the master cylinder T 5 Snap to Connect 1 Pushrod 2 Slave cylinder 4 Bolts 4 M8 x 1 25 mm torque 20 25 Nem Clutch Servo Fill Procedure Recommended methods are vacuum fill or pressure fill Refer 1 Clutch servo to OEM procedure A CAUTION Do not press or disengage clutch pedal when removing slave cylinder or clutch servo 30 General Information General Clutch Information Function of a Clutch Any modern day clutch whether designed for an automobile or heavy truck performs several i2. Install mounting bolts and torque to OEM specs A WARNING A CAUTION Do not let the transmission drop or hang Do not use excessive force If it unsupported in the driven discs This does not enter freely investigate can cause the discs to become distorted the cause of problem and make and the clutch to not release any necessary changes 27 Hydraulic Linkage Hydraulic Linkage Verify Linkage System Stroke Measure the release bearing position with the pedal up and pedal down to verify bearing travel The hydraulic linkage should allow for a minimum of 600 of yoke finger movement 500 560 for clutch release plus additional movement for clutch brake squeeze If the system does not provide enough movement of the release bearing the clutch will not adjust and the bearing will move away from the transmission and lose clutch brake squeeze If the system is operational clutch replacement may be nec essary If replacing the clutch you must adhere to OEM war ranty guidelines prior to claim disposition Master Cylinder Installation Master Cylinder Master cylinder may be mounted at any angle ranging from vertical to horizontal depending on application 5 1 Master cylinder 2 Reservoir 3 Pushrod 4 Bolts 2 M8 x 1 25 mm torque 20 25 Nem 5 To booster or slave Remote Reservoir Constant rise in hose from master cylinder to reservoir 28 T 5
3. mr Finger 6 e Release a Bearing Clutch Brake Lo Easy Pedal and Value Clutch Verify Free Play NOTE Hydraulic Systems will not have any free play Q Check distance between yoke tips and bearing wear pads This distance should be 1 8 3 2 m 55e 1 8 If distance is not 1 8 3 2 mm 3 2 mm go to Step 7 N e e A IMPORTANT Do not change bearing Yoke Release position Finger Bearing NOTE 1 8 3 2 mm distance will create free play in cab Free play in cab may be different on different truck makes models and years Q The truck linkage should allow for a minimum of 685 of yoke finger movement 125 for free play 500 for the bearing and 060 for clutch brake squeeze If it is necessary to increase the free play adjust upper pedal stop to raise or lower the pedal in the cab If this is not possible check the OEM parts manual to verify the correct clutch arm was installed at the factory Do not change free play by changing the bearing position Correct bearing position is 500 560 12 70 14 22 mm 22 Easy Pedal and Value Clutch Lubricate NOTE All clutches use a lithium base grease with a minimum of 325 F 163 C operating range meeting N L G I grade 1 or 2 Specs NOTE Apply ample grease that is visibly exiting the opening and co
4. 68 Nem D Remove the aligning tool Using a piece of 5 16 x 18 UNC x 3 threaded rod jack Install the jack screw into one of the screw install two nuts on four holes located adjacent to the one end and lock them clutch mounting bolts This forces together This will allow you the pressure plate forward clamping to turn the jack screw in and the discs and holding them in place out of the cover assembly Be sure the hole chosen as at the 6 o clock position to allow for removal after the transmission is installed A CAUTION Do not overtighten the jack screw Tightening more than 9 lbs ft can cause permanent clutch damage 26 UltraShift Install Transmission Check Transmission for Wear Replace any worn components Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely causing poor clutch release clutch drag Slide discs full length of shaft to check for twisted shaft splines A IMPORTANT Do not add lube to the input shaft splines Never seize or grease The discs must be free to slide Fasten Transmission to Flywheel Housing Position transmission so it is square to and aligned with engine Reconnect UltraShift wiring harness Mesh splines by moving transmission forward and rotating the input shaft Do not use excessive force Do not let the transmission hang unsupported in the discs o Remove the jack screw
5. Ibs ft can cause permanent clutch damage Remove the old pilot bearing Qo Remove the transmission supporting its weight to prevent 9 damage to the clutch discs away from the flywheel Remove the jack screw 9 Insert alignment shaft A WARNING and clutch jack An assembled clutch weighs about 182 Ibs 82 kg Avoid the risk of injury Use proper equipment when lifting a clutch A CAUTION When removing the clutch the flywheel side disc can fall off of the alignment shaft permanently damaging the driven disc 24 UltraShift Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or there will be premature clutch wear All gauge contact surfaces must be clean and dry Use a dial indicator and check the following Flywheel Face Runout Pilot Bearing Bore Runout o Position gauge amp p Secure dial o Put gauge finger in Secure dial finger So tha it indicator base contact with flywheel indicator base to contacts pilot housing face edge bearing bore Q Rotate flywheel one Rotate flywheel revolution Maximum one revolution runout is 008 20 mm Maximum runout is 005 13 mm Flywheel Housing 1 0 Runout Flywheel Housing Face Runout Secure dial indicator Put gauge finger secure indicator base to flywheel near the outer edge against flywheel housing pilot 1 0 base to cranks
6. N E e a Release Bearing Clutch L Brake e Adjust bearing position Easy Pedal Only Value Clutch Only While pedal is held down push adjusting While pedal is held down remove lockstrap and nut and turn move adjusting lug e f measurement was more than 560 e f measurement was more than 560 14 22 mm 14 22 mm turn adjusting nut clockwise move adjusting lug to the left shown e f measurement was less than 500 e f measurement was less than 500 12 77 mm 12 77 mm turn adjusting nut move adjusting lug to the right counterclockwise Adjusting Nut Adjusting Part number 125489 Lug y Lockstrap 20 Easy Pedal and Value Clutch Verify Clutch Brake Squeeze A WARNING Use a gauge long enough to keep hands away from moving parts Have an assistant insert 010 25 mm feeler gauge between the release bearing and the clutch brake Press the pedal down to the floor to clamp the gauge e f the gauge does not clamp readjust the truck linkage and move the yoke finger closer to the bearing Slowly let up on the pedal and measure the pedal position at the moment the gauge can be removed e f pedal is more than 1 25 4 mm from the floor readjust the truck linkage to move the yoke fingers further from the release bearing Repeat Step 4 0 Less than 1 25 4 mm d 21 e Yoke
7. the truck will have good engagement protection for the driveline long clutch life and minimal loss of torque 1 Checkthe Flywheel Bore 15 5 Clutch The fly wheel environment must be checked to make sure a clutch can be used with it The bore is important when deciding what type of driven disc to use The bore must be large enough to allow for a proper fit of the disc See chart below Measure bore size possem of Springs Bore size 8 spring 71 4 184 15mm 10 spring 89 16 217 48mm 7 spring 93 4 247 65 9 spring Mack eng only 9 3 4 247 65mm E Flywheel ngne YT 6 spring 93 4 247 65mm 2 Torque Capacity A clutch must be chosen that has a torque capacity that is greater than or equal to the peak torque of the engine This is very important today when an engine can be easily adjusted elec tronically to produce greater torque There are two factors in determining torque capacity These two factors are friction force and damper capacity e Friction force is a product of the cover assem blies clamp load also called plate load This factor was explained in the previous section and is stated as F f uNPr Determining the friction force is important because if this force is not greater than or equal to the peak torque of the engine the clutch will slip e Damper capacity is what allows the clutch to provide torsional protection for the entire drive line If the peak engine torque exceeds
8. 8 5 10 spring 10 0 6 and 7 spring Mack 9 spring NOTE Mack 9 spring for Mack engine only Install second disc onto aligning tool Follow the orientation instructions on the disc O Install intermediate plate into slots on the clutch cover Flywheel Side must face the flywheel Install disc onto aligning tool Follow the orientation instructions on the disc Insert aligning tool through bearing yellow shipping Q Install lock washers and mounting bolts in a bolts 7 16 x 14 UNC x 2 1 4 crisscross grade 5 finger tight Replace pattern studs with lock washers and bolts Remove the mounting bolts in a crisscross aligning tool pattern starting with a lower bolt 1 2 3 4 5 6 7 8 Torque to 40 50 Ibs ft 54 68 Nem Use a 1 4 flat nose punch to lightly tap four intermediate plate pins toward the flywheel Install Transmission Check Transmission For Wear Replace any worn components Cross Shaft and Bushings Excessive wear at these points can cause Transmission Bearing side loading on the sleeve bushing Retainer Cap bushing failures and yoke bridge contact A worn rough bearing with the clutch when the pedal is down retainer cap may cause the clutch brake to wear prematurely Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely causing poor clutch release clutch drag Slide discs full length of sh
9. Clutch Wear Clutch wear happens because the clutch discs slip relative to the engine flywheel and the pressure plate surface and in the case of a two plate clutch the intermediate plate during vehi cle launch and gear change As the clutch disc friction mate rial and mating flywheel and pressure plate surfaces wear the gage thickness of the clutch pack decreases moving the pressure plate closer to the engine flywheel This movement of the pressure plate causes the pressure spring s to elon gate and loose clamping load If clamping load is allowed to decrease beyond a critical point the clutch will be unable to carry full engine torque and slip Cover Assembly The cover assembly constructed of either stamped steel or cast iron is bolted to the flywheel It contains the pressure plate which is fitted to the cover with pressure springs It also contains the release bearing and levers which move the pres sure plate back and forth thereby making or breaking contact with the disc assembly General Information Driven Disc Eaton offers a variety of 14 and 15 5 driven disc designs The selection of driven discs depends on many factors Excessive torsional vibration can significantly reduce the life of all drivetrain components That s why Eaton has engineered soft rate dampers to reduce critical vibrations in today s elec tronic high horsepower engines Eaton recommends the use of soft rate dampers 7 spring or 6 spring
10. The springs used in these dampers are approximately 1 5 long and do not offer a large amount of deflection before coil lock takes place While these dampers were completely adequate for most heavy duty applications several years ago they are generally incapable of reducing the engine flywheel vibrations developed with slow speed elec tronically fueled engines The use of standard dampers in heavy duty applications has virtually ceased in OEM applica tions The trend is to use more capable soft rate dampers Soft Rate Dampers Soft rate dampers like the heavy duty 6 and 7 spring types offer much better protection against engine flywheel induced torsional vibration Their springs are characteristically longer than springs used in standard rate dampers and offer more deflection before coil lock occurs This larger spring deflection is equated to lower torsional spring rate With lower torsional rate the resonant frequency of the complete drivetrain is lowered usually to a point of a few hundred RPM below normal engine operating range With the addition of hysteresis or Coulomb dampening the energy expelled as the damper is exercised the magnitude of the vibrations is reduced further adding to the dampers benefit 32 lt P D gt eo D 3 D General Information Clutch Disc Friction Material Organic facings often called rag facings get their name from the high concentration of organi
11. V C T for all vehi cles over 1 000 ft Ibs Specifically Eaton offers driven discs with different numbers of springs in the center section of the damper 6 7 8 9 and 10 spring configurations are available The proper selection depends on many factors including the engine flywheel and transmission of the vehicle Facings The disc facings are critical to clutch life and performance because they directly receive the torque of the engine each time the clutch is engaged In general ceramic facings have greater heat tolerance and torque capacity than organic facings As such they engage quicker reduce slippage and deliver longer life Organic facings non asbestos are adequate for lower horse power on highway applications However Eaton recom mends ceramic facings for most applications Intermediate Plate The intermediate plate or center plate increases the torque capacity of the clutch by providing additional surface area for facing material and torque capacity The intermediate plate is driven by the clutch cover or by the flywheel on the 14 Easy Pedal Plus design Positive Separator Pin Eaton Fuller s Positive Pin Separator improves clutch life and performance by providing cooler operation smoother engagement and equal plate separation The pin restricts intermediate plate movement when the clutch is released giv ing constant gap on both sides of the plate therefore allow ing the driven discs to spin fr
12. and Mack 9 spring orientation instructions 11141 assembled NOTE Mack 9 spring for Mack engine only on the disc clutch o Install intermediate plate into slots on the clutch cover Flywheel Side must face the flywheel Install disc onto aligning tool Follow the orientation instructions on the disc Insert aligning tool through bearing e D Quies mounting bolts in a crisscross pattern starting with a lower bolt 1 2 3 4 5 6 7 8 Torque to 40 50 Ibs ft Install lock washers and 54 68 Nem _ mounting bolts 7 16 x M 14 UNC x 2 1 4 grade 5 Ha os 5 g finger tight Replace 5 8 9 5 15 9 mm a studs with lock washers from cover and bolts D Remove the aligning tool Be sure shipping blocks are removed use a 1 4 6 mm fiat nose punch to lightly tap four pins toward flywheel New EP Only Reman and Value clutches do not have pins Easy Pedal and Value Clutch For 14 Clutch Only Ensure the correct flywheel depth Super duty clutch only is 2 15 16 Install three 9 equally spaced Put front disc into anti rattle springs flywheel Flywheel a side must be toward engine Use new slots to put intermediate plate on pins Qu intermediate plate left Use 006 feeler gauge to check left pin clearance on all 6 drive pins NOTE Remove two set screws Straighten pins to increase clea
13. and engine braking The clutch pedal is used only when starting the engine launching the vehicle from a stop and when the vehicle slows to a stop The last function of the clutch is mitigating torsional vibra tions With any in line six cylinder engine there are three 3 distinct power pulses occurring during each revolution of the flywheel With each firing of a cylinder the flywheel speeds up then slows down very quickly resulting in a torsional vibra tion This vibration can damage drivetrain components in short order if left uncontrolled The coil springs in a driven disc damper absorb much of the vibration The resonant gen erally the least expensive drivetrain component is considered the fuse of the system Failure of a clutch damper section is usually an indication of a serious torsional vibration systems problem or shock loading due to driver abuse Clutches are assemblies made up of many different compo nents utilizing many different types of materials This section 31 describes the major components which make up a complete Eaton Fuller Clutch installation The following are the major components used to make up a clutch installation Cover Assembly contains pressure plate Intermediate Plate only in 2 plate clutches Driven Disc s Clutch Brake Neutral Idle Rattle Neutral idle rattle is a system issue It occurs when the engine is idling with the transmission in neutral and the clutch pedal in the up
14. flywheel opening Go to page 3 Step 1 If tab not at NEW position the bearing may have been pulled during installation causing an overadjust Go to page 1 In Vehicle Resetting Procedure Have assistant hold clutch pedal down Q Push pedal down and squeeze clutch brake 5 times to reposition bearing BX V While pedal is held down move wear tab to the left New position oe NOTE All adjustments must be done through access panel opening If tab will not move go to page 13 Remove shipping bolts NOTE This will remove the gap between the sleeve and the pin Let up on pedal DO NOT push pedal down again or wear tab will return to the wrong position o Install and tighten 4 shipping bolts 7 16 x 14 x 1 3 4 UNC c until they quit C turning gt Shipping 0 bolt RS Before After Ne No gap between sleeve and pin 11 Not Enough Free Pedal or No Clutch Brake J Too little travel Not enough brake squeeze Measure distance between release bearing and clutch brake o Use chart to find solution Measurement If distance is correct A90 560 rap 12 45 14 22 mm A If distance is More than 560 a gt 14 22 mm Clutch is set up correctly Clutch is not set up correctly Problem exists wi
15. position As the engine idles the firing pulses cause the flywheel to oscillate as it is rotating This oscillation is transmitted through the input shaft and into the transmission gearing This oscillation causes the transmission gears to impact one another resulting in a sometimes objectionable noise While this noise is an annoyance it is in no way dam aging to the transmission and other components In the past free travel dampers have been used to overcome this phenomenon As systems have changed in terms of mass inertia and fuel injection pressures free travel has become a less effective means of control Free travel simply stated is the free left or right rotation of the driven disc hub before engaging the clutch damper This first stage isolates some of the flywheel oscillation energy and prevents or reduces the idle rattle Pre damper technology is now available in some medium and heavy duty clutch applications and performs the same function as the free travel By adding a dampened first stage it is more effective at limiting neutral idle rattle Generally the pre damper springs are very small and softer in rate than the main damper springs In diagnosing neutral idle rattle complaints first try to fully depress the clutch pedal This will disconnect the engine from the transmission Secondly try raising the engine idle speed with the clutch pedal up This may smooth out the engine fir ing and may reduce or eliminate
16. the maintenance personnel a chance to make the necessary inspection internal clutch adjustment linkage adjustment and lubrica tions thereby avoiding possible clutch failures and breakdowns while on the road The importance of free pedal travel sometimes referred to as a pedal lash should be brought to the driver s attention as well as the mechanic This item should be included and commented on daily in the driver s report since clutch free pedal is the maintenance personnel s guide to the condition of the clutch and the release mechanism Clutch Adjustments Manual Adjustment The importance of proper and timely clutch adjustments and lubrication can not be over stated Internally adjusting the clutch properly and when needed will keep the clutch components in the proper position and extend the life of the clutch See the adjustment section for more information Solo Adjustment Free If your truck is equipped with an Eaton Fuller Solo Adjustment Free Clutch then the clutch will always be in proper adjustment Pos sible lubrication and inspection are needed See Inspection and Lubrication General Information When to Inspect the Clutch The clutch should be inspected during the regularly scheduled lubrication intervals as dictated in the Lubrication section or when one of the following occur e Clutch Free Pedal If the clutch free pedal is one half of OEM specifications not less than one half inch During normal clut
17. the noise If you have neutral idle rattle determine what clutch is installed in the vehicle It may already have a pre damper clutch in it If it is already equipped with a pre damper clutch then there is no benefit to changing the clutch General Information Solo Clutches The Eaton Fuller Solo is the industry s first adjustment free clutch With every push of the pedal Solo s innovative wear adjusting technology senses for wear and makes any adjust ments necessary Why There is No Need to Adjust Eaton Fuller Solo Clutches If the Solo Clutch is properly installed and the linkage is set up properly the Solo Clutch should never need internal or external adjusting The Solo Clutch automatically keeps the proper release bear ing position and clutch free pedal position with two opposing cams As the Solo Clutch wears the cams separate from each other keeping the proper release bearing position This in turn maintains the proper clutch free pedal position How it Works Eaton Fuller Solo s wear adjusting technology comes from two sliding cams With every push of the pedal the clutch senses for wear and makes any adjustments necessary The cams rotate to maintain the proper adjustment throughout the life of the clutch On top of the upper cam a clutch wear indi cating tab mirrors the cams movement to let you know when it s time to replace the clutch The result of Solo s constant adjustment is greater lo
18. 0 or call 1 800 826 HELP 4357 Lubrication Interval The DM UltraShift clutch does not require any lubrication or adjustment There is no clutch linkage associated with this product therefore there is no linkage adjustment or mainte nance requirements For recommended lubrication intervals see TCMT 0021 or call 1 800 826 HELP 4357 Copyright Eaton and Dana Corporation 2007 EATON AND DANA CORPORATION hereby grants its customers vendors or distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Roadranger E T N 2007 Eaton Corporation All rights reserved Printed in USA National Institute for UT SERVICE EXCELLENCE For spec ing or service assistance call 1 800 826 HELP 4357 24 hours a day 7 days a week Mexico 001 800 826 4357 for more time on the road Or visit our web site at www roadranger com Roadranger Eaton Dana and other trusted partners providing the best products and services in the industry ensuring more time on the road Eaton Corporation eTruck Components Operations Box 4013 Kalamazoo MI 49003 U S A www roadranger com
19. 3 Clutch Brake The clutch brake friction material is designed to operate with lubricant While lubricating the release bearing grease should purge from the housing and contact the clutch brake This is benefi cial for long clutch brake life If desired a small amount of grease could be applied to both sides of the clutch brake 4 Cross Shaft Bushings Lubricate both the left and the right cross shaft bushings per OEM recommen dations 5 Clutch Control Linkage Lubricate the clutch linkage bell cranks and pivot pins per OEM recommenda tions 6 Pilot Bearing The pilot bearing inside the flywheel is a sealed for life bearing and requires no lubrica tion Use a premium pilot bearing to prevent clutch drag and early bearing failures C 3 C 4 C 5 Suffix 37 Lube Tube Assembly The Eaton Fuller Lube Tube Assembly enables the release bearings in Eaton Fuller medium and heavy duty clutches to be greased without removing the bell housing inspection cover The Lube Tube Hose replaces the original zerk fitting on the release bearing and protrudes through the bell housing window Lube Tube Lengths Length in Inches Part Number 12 CLT012 9 CLTO09 8 CLTO08 T CLTOO7 6 CLTO06 Recommended Lubrication A CAUTION Incorrect grease and improper lube procedures will cause bearing failures bushing wearout yoke tip and bearing wear pad wear For a list of recommended lubricants see TCMT 002
20. E T N Fuller Heavy Duty Clutches Roadranger More time on the road Service Manual CLSM0200 January 2008 Solo Heavy Duty Easy Pedal Value Clutch UltraShift DM Heavy Duty Warnings and Cautions Repair Warnings The major cause of clutch failure is excessive heat Excessive heat generated between the flywheel driven discs intermedi ate plate and pressure plate can cause the metal to flow and the material to be destroyed If this occurs the clutch can burst which can cause property damage serious bodily injury or death In order to prevent clutch failure resulting from excessive heat 1 Do not exceed recommended vehicle loads 2 The clutch should only be used for the recom mended applications 3 Drivers should be properly trained in starting shift ing and operation of the clutch 4 Drivers should report erratic clutch operation as soon as possible to permit maintenance personnel to inspect adjust or lubricate as required 5 Mechanics must be familiar with proper clutch adjustment linkage adjustment lubrication and other maintenance troubleshooting procedures out lined in the Failure Analysis Guide When disassembling various assemblies lay all parts on a clean bench in the same sequence as removed to simplify and reduce the possibility of losing parts Since the cost of a new part is generally a small fraction of the cost of downtime and labor avoid reusing a questionable part that co
21. Hydraulic 28 General Information 31 17 i i 5 gt 53 e Out of Vehicle Resetting Out of Vehicle Resetting Procedure Remove the four 4 Support the clutch in an Center the ram and shipping bolts if they have o arbor press with the bearing press downward on the been installed facing down retainer until it comes to a stop Lock the ram in Note Make sure position there is at least 1 inch of space to allow the bearing to move down and to provide access to the E shipping bolts Oo Slide the wear indicator tab to the NEW position and hold it in place with a magnet install four 4 shipping bolts 7 16 x 14 x 1 3 4 UNC hex head Progressively tighten no air wrenches the four 4 shipping bolts criss cross pattern until the face of the pressure plate is 1 75 1 78 44 4 45 2 mm below the mounting surface Shipping Bolts 1 75 1 78 44 4 45 2 mm Q Reinstall the clutch using pM the original installation Note This important step will reset the instructions pressure plate spacers and allow the clutch to release after reinstallation Install Solo Heavy Duty 15 5 Clutch Installation Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or there will be premature
22. adjust the truck linkage to move the yoke fingers further from the release bearing Return to Step 4 Q 2 Less than 1 25 4 mm 9 Verify Free Play Q Verify there is free play in the cab If not the truck linkage is not providing enough stroke consult OEM manual IMPORTANT DO NOT RESET THE CLUTCH Do not change free play by readjusting the clutch linkage Lubricate Lubricate NOTE All clutches use a lithium base grease with a minimum of 325 F 163 C operating range meeting N L G I grade 1 or 2 Specs NOTE Apply ample grease that is visibly exiting the opening and contacts the transmission shaft This will lube the clutch brake and bushing when the pedal is pressed For additional lubrication information see TCMT 0021 Yoke Finger A CAUTION Failure to properly lubricate the bearing bushing will result in bearing and sleeve failures 9 Apply grease to input ejeuqn e Q Apply grease to the cross shaft bushings and linkage pivot points shaft and yoke fingers Input Shaft A IMPORTANT Do not add lube to the input shaft splines Never seize or grease The discs must be free to slide Solo Heavy Duty 15 5 Clutch Troubleshooting Symptom Driven Diagnostics If clutch is out of vehicle go to out of vehicle resetting procedu
23. aft to check for twisted shaft splines Do not add lube to the input shaft splines Never seize or grease The discs must be free to slide Release Yoke Worn fingers can cause bushing wear and yoke interference when the pedal is down Clutch Brake Replace Input Shaft Wear roughness can Measure Input Shaft reduce sleeve bushing life Length should be 8 657 219 89 mm nominal and not and cause it to come out greater than 8 71 221 23 mm Ref 1990 SAE handbook 4 36 106 Replace transmission bearing retainer cap if length is greater than 8 71 219 89 mm Do not excessively force the Do not use the cross shaft release lever transmission into the clutch assembly or a pipe over it to pull the or engine housing This will cause transmission into its final position damage to the splines of the rear disc Pulling the bearing too far during hub that is not warrantable If the discs installation can cause an overstroke do not slide freely in the input shaft causing the release bearing to move investigate the cause of the problem closer to the transmission less than and make any necessary changes If the 490 Follow the Out of Vehicle discs do not slide freely the clutch will Resetting Procedure on page 1 not release and the transmission will grind going into gear Do not let the transmission drop or NOTE Adjust the linkage until pushing hang unsupported in the driven discs the pedal down moves the bearing This c
24. an bend the discs and the clutch against the clutch brake Let up on the will not release causing damage that is pedal and measure the distance not warrantable between the bearing and clutch brake should be 490 560 Fasten Transmission to Flywheel Housing Put transmission in gear Be sure new clutch e Position transmission so it is brake has been installed square to and aligned with engine o Make sure that the yoke fingers remain in the up position until they are over the release bearing housing 5 22 O Mesh splines by moving transmission forward and gc rotating the output shaft A IMPORTANT Do not add lube to the input shaft splines Never seize or grease The discs must be free to slide Standard Yoke Solo XL Roller Yoke and Bearing and Bearing Install mounting bolts and torque to OEM specs A CAUTION Do not pull on release arm to install transmission This will cause the clutch to over adjust A WARNING Do not let the transmission drop or hang Do not force transmission against unsupported in the driven discs This clutch with yoke fingers in the UP can cause the discs to become distorted position This will break the cast and the clutch to not release webbing of the clutch causing damage that is not warrantable Do not use excessive force If it does not enter freely investigate the cause of problem and make any necessary changes Set up Adjust Clutch Lin
25. at a higher speed differential 4 Do Not Ride the Clutch Pedal Riding the clutch is very destructive to the clutch since a partial clutch engagement permits slippage and excessive heat Riding the clutch pedal will also put a constant thrust load on the release bearing which can thin out the lubricant and also cause excessive wear on the pads Release bearing failures can often be attributed to this type of operation 5 Do Not Slip the Clutch to Hold the Vehicle on an Incline This procedure uses the clutch to do the job 35 normally expected of the wheel brakes A slipping clutch accumulates heat faster than it can be dissi pated resulting in early failures Do Not Coast with the Clutch Released and Trans mission in Gear This procedure can cause high driven disc RPM through multiplication of ratios from the final drive and transmission It can result in throwing the facing off the clutch discs Driven disc speeds of over 10 000 RPM have been encoun tered in such simple procedures as coasting tractors down an unloading ramp While an ample safety fac tor is provided for normal operation the burst strength of the facing is limited Do Not Engage the Clutch while Coasting This procedure can result in tremendous shock loads and possible damage to the clutch as well as the entire drivetrain Reporting Erratic Clutch Operation Promptly Driv ers should report erratic clutch operation as soon as possible to give
26. c rubber and binder agents that make up their composition Fiberglass cord or similar material is woven into the material matrix and adds burst strength and improves friction and wear properties Asbestos has not been used in organic friction material since the early 1980 s Organic facings are used without exception in passenger car and light truck applications This is so because of smooth engagement properties and the relative light torque loads imposed on the clutch In general organic friction material lacks in performance in wear rate coefficient of friction ability to carry torque and resistance to fade abuse tolerance when compared to cera metallic friction material The use of organic friction material in heavy vehicles has significantly declined over the past decade Wear life and its maximum limit to 1 400 ft Ibs 1892 Nem of torque in 15 5 clutches are the primary reasons Cera metallic Ceramic friction facings are composite mate rial copper sand and other friction modifiers and binder agents The dry raw materials are mixed in bulk poured into die cavities compressed sintered in an controlled atmo sphere then brazed into a steel backer plate to facilitate rivet attachment to the driven disc Compared to organic friction material cera metallics have improved performance in the areas of wear rate resistance to fade abuse tolerance and coefficient of friction ability to carry torque It is for this rea son t
27. ch use the release bearing will move toward the fork fingers and reduce in cab free pedal e Clutch Is Slipping If the clutch is slipping it may require adjustment If proper internal clutch adjuster and external clutch linkage adjustment has been made and the clutch still slips it is likely worn beyond its useful life and needs replacement Inspection for Clutch Life If your vehicle is equipped with a Eaton Fuller Solo or Solo XL Extended Lube Clutch the clutch is equipped with a clutch wear indicating tab that can be seen through the inspection window To calculate the expected life of a Solo apply a paint mark indicating the start point of the clutch wear indicating tab Record the mileage when this mark was made After a few months reinspect the position of the clutch wear indicating tab and record the new mileage The difference between the two readings can be used to estimate when the clutch will need to be replaced For Example Starting Mileage 10 000 After six 6 months mileage 75 000 Clutch wear indicating tab movement 625 16 mm 75 000 10 000 65 000 miles 65 000 miles 625 104 000 miles per inch of tab movement 3 5 remaining tab movement 3 5 remaining tab movement X 104 000 miles per inch of tab movement 364 000 expected clutch life Designing a Clutch for a Specific Application There are three parts to designing a clutch for a specific appli cation If the correct clutch is chosen
28. clutch wear Remove old pilot bearing All gauge contact surfaces must be clean and dry Use a dial indicator and check the following Flywheel Face Runout Pilot Bearing Bore Runout Q Secure dial Secure dial indicator base mE iod indicator base to housingface edge o Position gauge finger so that it contacts pilot bearing bore Q Rotate flywheel one Rotate flywheel revolution Maximum one revolution runout is 008 20 mm Maximum runout is 005 13 mm Flywheel Housing 1 0 Runout Flywheel Housing Face Runout Secure dial indicator Put gauge finger secure indicator base to flywheel near the outer edge against flywheel housing pilot 1 0 base to crankshaft o Put gauge finger in contact with Rotate flywheel Rotate flywheel one face of flywheel one revolution revolution Maximum housing Maximum runout runout is 008 20 mm is 008 20 mm Install Clutch to Flywheel Install Clutch to Flywheel Use the Eaton Fuller Clutch An assembled clutch weighs about Selector Guide CLSL1310 to make sure 150 Ibs 68 kg Avoid the risk of injury Use you have the right clutch proper equipment when lifting a clutch Measure the flywheel bore Use the Eaton Fuller Clutch Selector Guide to verify that the damper will fit into the flywheel bore install two 7 16 x 14 UNC x 5 studs into upper mounting holes Install assembled clutch 7 0 8 spring
29. eely 6 Position Kwik Adjust Eaton Fuller s Easy Pedal Plus 14 and Easy Pedal 2000 15 5 Clutches feature the Kwik Adjust component and the easy to reach external manual adjustment mechanism that allows for quick adjustment of release bearing travel without the use of special tools or the need to remove any bolts Using a common box end wrench simply depress the Kwik Adjust bolt and turn the standard 6 point hex head adjustor as needed Clutch Brakes Clutch brakes are designed to extend the life of a vehicle s transmission by eliminating damaging gear clash while reduc ing the effort required to shift into first or reverse from a standstill Eaton offers two separate clutch brake options e Torque Limiting e Kwik Konnect Torque Limiting Clutch Brake The Eaton Fuller Torque Limiting Clutch Brake has a self con tained torque limiting feature which prevents tang breakage from driver misuse of the clutch brake e Part Number 127740 1 75 spline e Part Number 127760 2 spline Kwik Konnect Two Piece Clutch Brake The two piece clutch brake provides cooler operation than competitive clutch brakes It is designed for service applica tions and can be quickly installed without removing the trans mission 34 D EL 3 D General Information Factors that Effect Clutch Performance Excessive slipping is the major cause of clutch failure Extreme op
30. erating temperatures can cause the clutch to fail because the heat generated between the flywheel driven discs intermediate plate and pressure plate is high enough to cause the metal to flow and the friction material to be destroyed An improperly adjusted or slipping clutch will produce suffi cient heat to rapidly burn up There are many factors which have significant impact on clutch life e Application torque capacity e GCW Weight e Number of starts per day e Maintenance Adjustment 1 Starting the Vehicle in the Proper Gear The cor rect gear will allow you to start the vehicle with your foot off the throttle 2 Gear Shifting Techniques Many drivers upshift into the next gear or even skip shift into a higher gear before the vehicle has reached the proper speed This type of shifting is almost as damaging as starting off in a gear that is too high since the engine speed and vehicle speeds are too far apart requiring the clutch to absorb the speed difference as heat 3 Excessive Vehicle Overload or Overloading the Clutch Clutches are designed and recommended for specific vehicle applications and loads These limitations should not be exceeded Excessive or extreme overloading is not only damaging to the clutch but to the entire vehicle powertrain as well If the total gear reduction in the powertrain is not suffi cient to handle excessive overloads the clutch will suffer since it is forced to pick up the load
31. haft 2 Put gauge finger in contact with Rotate flywheel Rotate flywheel one face of flywheel one revolution revolution Maximum housing Maximum runout runout is 008 20 mm is 008 20 mm 25 UltraShift Install Clutch to Flywheel Note If installing a new DM follow the installation directions that are provided in the box An assembled clutch weighs about 182 Ibs 82 kg Avoid the risk of injury Use proper equipment when lifting a clutch 10 0 6 spring 7 spring Install new pilot bearing Install two 7 16 x 14 UNC x 5 studs into upper mounting holes Using clutch jack or other lifting device install assembled clutch o Measure the flywheel bore to verify that the damper will fit into the flywheel bore Insert aligning tool through 3 DM Clutch and rear disc install second disc onto aligning tool Follow the A WARNING orientation instructions The intermediate plate is bolted on the disc to the cover assembly and the rear driven disc is held in place x between the pressure plate and intermediate plate DO NOT UNBOLT the intermediate plate from the cover assembly Q Install lock washers and mounting bolts 7 16 x 14 UNC x 2 1 4 grade 5 finger tight Replace studs with lock washers and bolts Q mounting bolts in a crisscross pattern starting with a lower left bolt 1 2 3 4 5 6 7 8 Torque to 40 50 Ibs ft 54
32. hat cera metallics make up the vast majority of OEM builds Clutch Slippage Slippage will cause significant heat build up and rapid wear of the clutch pack If the clutch pack temperature raises beyond the facing threshold temperature the facing may disintegrate Slippage is the result of loss of clamp load due to lack of adjustment loading the clutch beyond its design torque rat ing or the clutch has reached the end of its design life With the ability to re rate an electronic controlled diesel engine it is quite easy to delivery torque to the clutch beyond its design capacity Before an engine re rating is performed confirm that the clutch and other drivetrain components are capable of carrying the increased torque and power 33 Clutch Torque Capacity It is imperative to understand the factors that influence fric tion force because this device transmits torque via friction The fundamental equations that describes friction is F f uN Where F f Force due to friction U Coefficient of friction N Load applied to the friction interface T F f r Since torque T is equal to force friction F f multiplied by the moment arm R distance from application of force to center or rotation must be known To exactly calculate the moment arm the mean radius of a clutch R integration must be per formed However for clutches in the size range offered by Eaton the calculation can be simplified to ID OD 4
33. he cam tab does not move there is not enough release bearing travel to allow the cams to seperate In this case loosen the transmission and install 1 2 spacers between the flywheel housing and bell housing With the spacers in place push the clutch pedal to the floor while someone pushes the cam tab to the new position Once the tab is in the new position release the clutch pedal and remove the spacers Torque the transmission mounting bolts Release Bearing Measure the release bearing travel Install 4 shipping bolts and progressively tighten by hand until they bottom out Rotate the engine to access all 4 bolts 15 1 2 Solo use 7 16 x 14 UNC x 1 3 4 Stamped 14 Solo use 3 8 x 16 UNC x 1 1 4 Remove the 4 shipping bolts The release bearing and sleeve will move forward towards the engine when the bolts are removed The Solo is now in the new position 9 With the free pedal removed push the clutch pedal down at least 5 times Make sure the clutch release bearing contacts the clutch brake While you enage and release the clutch the cab free pedal will increase This indicates the Solo is adjusting to the environment Measure the distance between the clutch brake and the release bearing It should be between 0 490 and 0 590 Verify Clutch Brake Squeeze WARNING Use a gauge long enough to keep hands away from moving parts Have an assis
34. kage Q Hydraulic Linkages Skip to Step 2 Mechanical Linkages Only Adjust the clutch linkage until the yoke fingers contact the release bearing zero free play in cab Press the pedal to the floor up to 5 times this Moves release bearing slightly closer to the transmission Gains free play in cab ox 5X Pd v Release Bearing 500 560 12 70 14 22 mm With the pedal up measure the distance between the release bearing and the clutch brake The correct distance should be 500 560 12 70 14 22 mm e f the distance is more the 560 14 22 mm return to Step 1 and readjust the clutch linkage e f the distance is less the 500 12 70 mm see Troubleshooting on page 9 Verify Clutch Brake Squeeze A WARNING Use a gauge long enough to keep hands away from moving parts Oo Have an assistant insert 010 25 mm feeler gauge between the release bearing and the clutch brake Press the pedal down to the floor to reclamp the gauge e f the gauge does clamp readjust the truck linkage and e l e move yoke fingers closer to 7 Release the bearing Finger l4 Bearing Slowly let up on the pedal and measure the pedal position at the Clutch moment the gauge can be removed Brake e If pedal is more than 1 25 4 mm from the floor re
35. mportant tasks allowing for safe and convenient operation of the vehicle In a vehicle powertrain the clutch is the device that interrupts the flow of power from the engine flywheel to the transmis sion To start a gasoline or diesel engine the flywheel must be able to turn freely without propelling the vehicle By disengag ing the clutch the drivetrain is effectively disconnected from the rotation of the flywheel allowing the engine to start Manual transmissions whether synchronized synchromesh or non synchronized constant mesh require an interruption of engine torque to complete a gear change To make a gear change the clutch pedal is depressed breaking torque This is followed by altering engine speed to more closely match the transmission input shaft clutch disc speed After the proper gear is selected the clutch pedal is then slowly released As the clutch disc s are compressed the relative slip speed between the flywheel and the transmission input shaft reaches zero and the clutch is completely engaged and capable of car rying full engine torque With non synchronized gearboxes double clutching a momentary partial engagement of the clutch made while the transmission is in neutral is often nec essary to allow rotational speeds of gears to become the same and complete the gear change With the advent of transmission automation breaking torque and altering flywheel speed is accomplished via electronic throttle control
36. n until they are over the release bearing housing o Mesh splines by moving transmission forward and rotating the output shaft Do not use excessive force Do not let the transmission hang unsupported in the discs Install mounting bolts and torque to OEM specs NOTE If you have a hydraulic linkage go to Page 28 A CAUTION Do not let the transmission drop or hang Do not pull on release arm to install unsupported in the driven discs This transmission This will cause the clutch can cause the discs to become distorted to over adjust and the clutch to not release Do not force transmission against IMPORTANT clutch with yoke fingers in the UP Do not add lube to the input shaft splines Never position This will break the cast seize or grease The discs must be free to slide ee d Do not use excessive force If it does not enter freely investigate the cause of problem and make any necessary changes 19 Easy Pedal and Value Clutch Set up Adjust Bearing Position 1 Measure the distance between the release bearing and the clutch brake e f the distance is correct 500 560 12 70 14 22 mm then Verify Clutch Brake Squeeze Step 4 e f the distance is not between 500 560 12 70 14 22 mm then Change Bearing Position Step 2 N 500 560 12 70 14 22 mm o Have an assistant hold down clutch pedal
37. ngevity and a reduction in mainte nance and labor costs Clutch Disc Dampening Characteristics A key function of a clutch is to mitigate naturally occurring vibrations of the engine flywheel from reaching the transmis sion and the other components further down the drivetrain This is accomplished by employing torsional spring dampers to the clutch pack These springs take the form of coil springs configured inside the clutch disc that compress with the application of torque The torque path through the damper begins at the friction interface at the facings proceeds to the steel carrier disc and moves into the disc reinforcing plates where the springs are located The springs are compressed transmitting force to the spring covers which are rigidly attached to the hub Torsional rate is defined as the amount of torque required per degree of center hub rotation There are three basic categories of torsional rates for clutch dampers rigid standard soft Rigid and Clutch Discs Rigid discs and clutch discs with no spring package whatsoever act as a nearly direct link from the engine flywheel to the transmission and offer no protec tion against torsional vibration Their use should be limited to older mechanically fueled engines where clutch replacement cost is paramount over long component life Rigid clutch discs are never used in new OEM applications Standard Dampers Standard dampers include all 10 spring and most 8 spring types
38. ntacts the transmission shaft This will lube the clutch brake when the pedal is pressed For additional lubrication e information see TCMT0021 Yoke Finger Failure to properly lubricate the bearing bushing will Q result in bearing and sleeve failures Apply grease to input shaft and yoke fingers Apply grease to the cross shaft bushings and linkage pivot points Input Shaft A IMPORTANT Do not add lube to the input shaft splines Never seize or grease The discs must be free to slide 23 UltraShift UltraShift DM Heavy Duty Clutch Remove Clutch A WARNING An assembled clutch weighs about 182 Ibs 82 kg Avoid the risk of injury Use proper equipment when lifting a clutch Prior to removing the transmission rotate the engine until one of the jack screw locations can be viewed through the clutch housing inspection opening o Using a piece of 5 16 x 18 UNC x 3 threaded rod jack screw install two nuts on one end and lock them together This will allow you to turn the jack screw in and out of the cover assembly Install the jack screw into one of the four holes located adjacent to the clutch mounting bolts This forces the pressure plate forward clamping the discs and holding them in place CAUTION p Do not overtighten the jack screw Tightening morethan9
39. rance and reinstall set screws Do not file slots Install second Ors onto install two 3 8 x 2 1 2 flywheel intermediate nto flywheel studs into upper mounting Follow the plate onto ae n holes orientation drive pins instructions diclus on the disc on the disc side cover over insert aligning too aligning tool through discs tighten mounting bolts in a crisscross pattern starting with o 77 install lock washers and mounting a lower bolt 1 2 3 4 5 6 7 8 bolts 3 8 x 1 1 4 grade 5 finger Torque to 25 35 Ibs ft ge wem tight Replace studs with lock 34 47 Nem Remove the aligning tool Be sure shipping blocks are removed 17 Easy Pedal and Value Clutch Install Transmission Check Transmission For Wear Replace any worn components Transmission Bearing Retainer Cap Cross Shaft And Bushings A worn rough bearing retainer cap may Excessive wear at these points can cause cause the clutch brake to wear side loading on the sleeve bushing prematurely bushing failures and yoke bridge contact with the clutch when the pedal is down Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely causing poor clutch 4 release clutch drag Slide discs full length of shaft to check for twisted shaft splines A IMPORTANT Do not add lube to the input shaft splines Never sei
40. re on page 1 Based on your symptom the chart will direct you to the correct solution V Too Much Free Pedal Not Enough Free Pedal Go to page 10 Go to page 12 ss ite Pedal travels too far before engaging Pedal travels too little before engaging clutch Clutch does not disengage the clutch AW No Clutch Brake vi Too Much Clutch Brake X Go to page 10 Go to page 12 J UD bs Not enough Too much brake squeeze brake squeeze Too Much Free Pedal or Too Much Clutch Brake 5 Ph i much To h Too om uc travel brake squeeze Measure distance between release bearing and clutch brake fuljooysayqnosy Use chart to find solution Problem exists with truck linkage Repair If distance is correct Clutch is V 490 560 Ed set up correctly according to specifications 12 45 14 22 mm Hydraulic Linkage Go to page 28 If clutch was factory installed and was never If distance is Clutch is not d or if clutch df cd SEUD CONSCI removed or if clutch was removed from engine Less than 490 p and reinstalled Go to page 11 12 45 mm If new reman clutch was installed and it never operated properly check wear tab position If tab at NEW position disc installed incorrectly Go to page 3 Step 4 and 5 damper is too large for the
41. tant insert 010 25 mm feeler gauge between the release bearing and the clutch brake Press the pedal down to the floor to clamp the gauge e f the gauge does not clamp e readjust the truck linkage and move the yoke finger closer to the bearing Finger o Slowly let up on the pedal and measure the pedal position at the moment the gauge can be removed e f pedal is more than 1 25 4 mm from the floor readjust the truck linkage to move the yoke fingers further from the release bearing Repeat Step 4 Less than 1 25 4 mm Shipping Bolt Nin 3 Tamper Proof NOI p Bolt D Adjust the clutch linkage to achieve 1 8 clearance between the release yoke and the release bearing Verify proper clutch brake squeeze Shipping Bolts If the release bearing travel is still greater than 0 590 between the clutch brake and the release bearing repeat steps 7 and 8 e Release Bearing gt Clutch Brake 14 1 n Easy Pedal and Value Clutch Easy Pedal and Value Clutch Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or there will be premature clutch wear Remove old pilot bearing All gauge contact surfaces must be clean and dry Use a dial indicator and check the following Flywheel Face Runout Gp Sec
42. th truck linkage Repair according to OEM specifications Hydraulic Linkage Go to page 28 If clutch was factory installed and was never removed Mechanical Linkage Go to page 13 Hydraulic Linkage Go to page 28 If clutch was removed from engine and reinstalled Go to page 6 Setup If new reman clutch was installed and it never operated properly Go to page 6 Setup 1 n lt In Vehicle Resetting Procedure Using the Solo Resetting Tool 13 Tool Part Code CLMTO0001 amp Determine if the release bearing travel is correct Measure the distance between the clutch brake and the release bearing with the clutch pedal up If the measurement is between 0 490 and 0 590 the Solo has set itself correctly NOTE Yoke gap only applies to mechanical linkage Most hydraulic linkages operate without yoke gap o9 If the release bearing travel is less than 0 490 the Solo must be reset A common cuase of this is the transmission was pulled in with the release arm during clutch installation Rotate the engine so that the cam tab can be reached through the transmission inspection opening 0 Push the clutch pedal to the floor While the clutch pedal is pushed to the floor have someone push the cam tab to the new position using finger pressure or the Solo tool Once the cam tab is pushed to the new position you can release the clutch pedal NOTE If t
43. this capacity the driveline will be abused This abuse will cause faster wear and possible destruction of driveline components Since damper capacity is a product of the springs used in the damper changing the number and type of springs changes the stiffness of the entire system 3 Application Service replacement clutches should have the same plate loads damper and friction mate rial Substituting from the original could shorten the life of the clutch and drivetrain components 36 lt P D gt D D _ 3 D General Information Preventive Maintenance Overview To ensure long life and proper operation of the release mech anism of the clutch it is important to properly lubricate the following areas Lubrication 1 Release Bearing The cast iron bearing housing will be equipped with either a standard grease fitting or a lube tube extension If a lube tube is not present it is necessary to remove the inspection cover to gain access to the grease fitting Apply grease until it purges from the rear of the housing Grease on the clutch brake friction surface and the transmission input shaft will extend the life of the clutch brake and bronze bushings inside the release sleeve 2 Release Bearing Wear Pads Where the release fork contacts the bearing housing there are small hardened steel pads Apply a small amount of grease to the wear pads where the clutch release fork con tacts
44. uld lead to additional repairs and expense Use of other than recommended tools parts and instructions listed in this manual may place the safety of the service tech nician or vehicle driver in jeopardy The removal and installation procedure described for each component may vary for your vehicle For Solo only install shipping bolts before removing clutch A IMPORTANT For service information and assistance call the Roadranger Help Desk at 1 800 826 HELP 4357 Mexico 01 800 826 HELP 4357 You may also find more information about Eaton Fuller Clutches at www Roadranger com Every effort has been made to ensure the accuracy of the information contained in this manual However Eaton Corpo ration makes no warranty expressed or implied based on the information provided Table of Contents Table of Contents i Out of Vehicle Resetting Procedure 1 Solo Heavy Duty 15 5 Clutch d x atte m a thawte E Te hdd 2 6 CUOCO dae wna 8 Troubleshooting 00 cece IRI 9 Easy Pedal and Value Clutch posce PODES bake a Db A 15 JH T 20 MUSEI iin tay ore Bow waw 23 UltraShift DM Heavy Duty Clutch REMOVE 2 mou deck rr twa death DA a hix 24 ripe 25
45. ure dial Put i vec gauge finger in indicator base contact with flywheel to flywheel face near the outer housing face edge Rotate flywheel one revolution Maximum runout is 008 20 mm Flywheel Housing 1 0 Runout Q Secure dial indicator Put gauge finger against flywheel housing pilot I D base to crankshaft Rotate flywheel one revolution Maximum runout is 008 20 mm 15 Pilot Bearing Bore Runout Secure dial i indicator base to flywheel housing ae Rotate flywheel one revolution Maximum runout is 005 13 mm Flywheel Housing Face Runout Secure dial indicator base to flywheel near the outer edge Put gauge finger in contact with Rotate flywheel face of flywheel one revolution housing Maximum runout is 008 20 mm Easy Pedal and Value Clutch Install Clutch to Flywheel Use the Eaton Fuller Clutch Selector Guide An assembled clutch weighs about 150 Ibs CLSL1310 to make sure you have the 68 kg Avoid the risk of injury Use proper right clutch equipment when lifting a clutch For 15 5 Clutch Only Easy Pedal shown 0 Measure the flywheel bore Use the Eaton Fuller Clutch Selector Guide to verify that the damper will fit into the install two 76 x 14 7 0 8 spring install second disc onto UNC x5 studs into 8 5 10 spring aligning tool Follow the UPPer mounting holes 10 0 6 spring 7 spring
46. ze or grease The discs must be free to slide Release Yoke Worn fingers can cause bushing wear and yoke interference when the pedal is down Clutch Brake Replace Measure Input Shaft Length should be 8 657 219 89 mm nominal and not greater than 8 71 221 23 mm Ref 1990 SAE handbook 4 36 106 Replace transmission bearing retainer cap if length is greater than 8 71 219 89 mm A CAUTION Input Shaft Wear roughness can reduce sleeve bushing life and cause it to come out Do not let the transmission drop or Do not excessively force the hang unsupported in the driven discs transmission into the clutch assembly This can bend the discs and the clutch or engine housing This will cause will not release causing damage that is damage to the splines of the rear disc not warrantable hub that is not warrantable If the discs do not slide freely in the input shaft investigate the cause of the problem and make any necessary changes If the discs do not slide freely the clutch will not release and the transmission will grind going into gear Easy Pedal and Value Clutch Fasten Transmission to Flywheel Housing Transmission installation and clutch set up procedures are the same for the 14 and 15 5 clutch Put transmission in Position transmission gear Be sure new so it is square to and clutch brake has been aligned with engine installed Que sure that the yoke fingers remain in the up positio
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