Measure Engine Flywheel Housing and Flywheel Engine flywheel housing and flywheel must meet these specifications or there will be premature clutch wea...
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4
Set-up and Lubricate
Installation Procedure
Adjust Bearing Position 1 Measure the distance
2 To change bearing position, you must internally adjust the clutch. Push pedal
between the release bearing and the clutch brake. The correct distance should be 0.500" – 0.560" (12.70 – 14.22 mm). If correct go to Step 3. Transmission
gauge between the release bearing and the clutch brake. Press the pedal down to clamp the gauge. • If the gauge does not clamp, adjust linkage to achieve clutch brake squeeze then recheck Step 3.
check the pedal position at the moment the gauge can be removed.
Release bearing
• If the pedal is less than 1/2" (12.7 mm) or more than 1" (25.4 mm) from the floor when the gauge can be removed, readjust the linkage. (Repeat Steps 3 and 4.)
Clutch brake
Feeler gauge
1/2" – 1" (12.7 – 25.4 mm)
Eaton Vehicle Group P.O. Box 4103 Kalamazoo, MI 49003 USA 800-826-HELP (4357) www.eaton.com/roadranger
1
Copyright Eaton, 2016. Printed in USA Reference Materials CLSM200 and CLSL1511
Measure
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:
Verify Free-Play 5 Check distance
between yoke tips and bearing wear pads. This distance should be 1/8" (3.2 mm).
Eaton 14" and 15.5" Heavy-Duty Manual Adjust Clutch CLMT1351 US-EN May 2016
TO
Release bearing
and hold pedal down when adjusting. Follow instructions for Kwik-Adjust or Value Clutches. . Value Clutch Kwik-Adjust Clutches Remove lockstrap, then rotate adjusting lugs Push and turn adjusting nut. left to move bearing toward transmission. Clockwise moves the bearing Replace lockstrap. toward transmission.
6 To change the yoke finger
and bearing wear pads clearance, adjust the upper pedal stop to raise or lower the pedal in the cab.
Yoke tips
Do not change Bearing bearing position. wear pads
Flywheel Face Runout
Upper pedal stop
Secure dial indicator base to flywheel housing face. Put gauge finger in contact with flywheel face near the outer edge. Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm).
1/8" (3.2 mm)
Flywheel Housing I.D. Runout
Secure dial indicator base to crankshaft. Put gauge finger against flywheel housing pilot I.D. Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm).
Lubricate
Apply ample grease that visibly exits the opening and contacts the transmission shaft. This will lube the clutch brake when pedal is pressed.
7 Apply grease to the
input shaft and yoke.
8 Apply grease to the
cross shaft bushings and linkage pivot points.
9 Grease the release bearing until
grease purges from the rear of the release bearing onto the input shaft.
Transmission
Important: Eaton recommends the use of Roadranger EP2 for release bearing lubrication, or an equivalent Lithium Complex , NLGI #2 or #3 grease with a NLGI LB/GC performance rating and a dropping Point temperature of 2200 C (4280 F) or higher. Failure to use the proper grease may affect bearing life and void the warranty coverage on your Eaton product.
Pilot Bearing Bore Runout
Secure dial indicator base to flywheel housing face. Position gauge finger so that it contacts pilot bearing bore. Rotate flywheel one revolution. Maximum runout is 0.005" (0.13 mm).
Flywheel Housing Face Runout
Secure dial indicator base to flywheel near the outer edge. Put gauge finger in contact with face of flywheel housing. Rotate flywheel one revolution. Maximum runout is 0.008" (0.20 mm).
2
3
Install Clutch to Flywheel
For 15.5" clutch only:
3 Install disc
onto aligning tool. Follow the orientation instructions on the disc.
1 Measure the
flywheel bore. Use the Eaton Clutch Selector Guide (CLSL1511) to verify that the damper will fit into the flywheel bore.
intermediate plate into slots on the clutch cover. Flywheel Side must face the flywheel.
5 Install second disc onto aligning tool. Follow the orientation instructions on the disc.
8
Check Transmission For Wear
6 Install two 7/6" x 14 UNC x 5"
Replace any worn components.
studs into upper mounting holes. Install assembled clutch. Important: Use the Eaton Clutch Selector Guide (CLSL1511) to make sure you have the right clutch. Caution: An assembled clutch weighs about 150 lbs. (68 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch.
6
4
2 Insert aligning tool
4 Install
2
through bearing.
9 Verify bearing position is
TO
PR
7
DE
3
10 Remove the aligning tool.
bolts (7/16" x 14 UNC x 2 1/4" grade 5) finger tight. Replace studs with lockwashers and bolts.
1 Ensure the correct flywheel depth is 2-15/16".
equally spaced anti-rattle springs
7 Install
intermediate plate onto drive pins.
disc into flywheel. Follow the orientation instructions on the disc.
Super-duty clutch only:
3 Install three
BOLT ESS
nose punch to lightly tap four pins toward flywheel.
8 Install second
flywheel. Flywheel side must be toward engine. Use new slots to put intermediate plate on pins.
Transmission Bearing Retainer Cap A worn/rough bearing retainer cap may cause the clutch brake to wear prematurely.
6 Install disc
into flywheel. Follow the orientation instructions on the disc.
Cross Shaft and Bushings Excessive wear at these points can cause side loading on the sleeve bushing, 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 release (clutch drag). Slide discs full length of shaft to check for twisted shaft splines.
Release Yoke Worn fingers can cause bushing wear and yoke interference when the pedal is down.
Clutch Brake Replace.
Input Shaft Wear (roughness) can reduce sleeve bushing life and cause it to come out.
11 Use a 1/4" (6mm) flat
bolts in a crisscross pattern starting with a lower bolt. Torque to 40–50 lbs. ft. (54–68 N•m).
2 Put front disc into
TO
RN TU
8 Progressively tighten mounting
7 Install lock washers and mounting
For 14" clutch only:
Be sure shipping blocks are removed.
PR
5
3/8"–5/8" (9.5–15.9mm) from cover.
DE
BOLT ESS
RN TU
1
Install Transmission
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).
Fasten Transmission To Flywheel Housing
5 Install two 3/8" x 2 1/2"
studs into upper mounting holes.
Transmission installation and clutch set-up procedures are the same for the 14" and 15.5" clutch.
1 Put transmission in gear. Be sure new clutch brake has been installed.
2 Make sure that the yoke
3 Position transmission so it is square to and aligned with engine.
fingers remain in the up position until they are over the release bearing housing.
9 Insert aligning tool
10 Slide cover over
through discs.
aligning tool.
RN TU
BOLT SS
TO
DEP RE
6
4 8
2
4 Turn intermediate
4 Mesh splines by moving transmission
12 Progressively tighten mounting TO
7
PR
BOLT ESS
RN TU
1
DE
plate left. Use 0.006" feeler gauge to check left pin clearance on all 6 drive pins. Note: Straighten pins to increase clearance. Do not file slots.
5
3
11 Install lock washers and mounting
bolts (3/8" x 1 1/4" grade 5) finger tight. Replace studs with lockwashers and bolts.
bolts in a crisscross pattern starting with a lower bolt. Torque to 25–35 lbs. ft. (34–47 N•m).
13 Remove the aligning tool. Be sure shipping blocks are removed.
forward and rotating the output shaft. Do not use excessive force. Do not let the transmission hang unsupported in the discs.
