Service and Installation Instructions

INSTALLATION INSTRUCTIONS
EATON FULLER TYPE STAMPED ANGLE-SPRING
TWO PLATE CLUTCHES

1. Check the condition of the flywheel. If it is cracked or warped, refer to the manufacturers recommendations concerning resurfacing or replacement.

2. Check pilot bearing conditions and fit in flywheel. It is always recommended to replace the pilot bearing.

3. Check the transmission main drive gear spline for excessive wear. Worn splines will prevent clutch discs from sliding freely.

4. Make sure that the drive pins are square with the friction face of the flywheel. The constant pounding of the old center plate may have changed the position of these pins. Make sure that all of them are checked using the proper alignment tool. It is always recommended to replace the drive pins.

5. Install two guide studs (3/8-16 thread and 2-1/2” long) at the eleven (11) and one (1) o’clock positions.

6. Install the front disc by inserting the aligning tool through the spline and into the pilot bearing and make sure that the side marked flywheel side faces the engine.

7. Install the intermediate plate over the drive pins. Center plate must “float” freely on the pins. If you are installing a “super-duty clutch” be sure to install 3 anti-rattle springs, spacing them equally between the drive pins, with the rounded sections facing the flywheel.

8. Install the rear disc by sliding over the aligning tool with long part of hub towards the transmission. Make sure that the side marked pressure plate side faces the transmission.

9. Position the cover assembly on flywheel by sliding it over the alignment shaft and guide studs. Start six bolts with lock washers and tighten finger tight. Lightly tap the aligning tool to make sure that it is centered and seated into the pilot bearing. Replace the two guide studs with bolts.

10. Tighten the bolts to 35-40 ft. lbs. evenly all around, making sure that the cover assembly seats properly in the flywheel.

11. Remove all the blocks under the release bearing cage.

12. Remove the alignment shaft.

13. Position the clutch brake on the main drive gear.

14. Install the transmission using extreme care not to hang the weight of the transmission on the clutch. The discs will bend, causing non-release. Locate the release yoke in the proper relation to the release bearing housing as the transmission is moved into place.

15.  The release bearing housing has been pre-packed with some grease, however it must still be lubricated when the clutch is installed or premature failure may occur. Do not over grease as the excess will find its way to the clutch friction material.

ADJUSTMENT OF TWO PLATE PULL TYPE CLUTCH

1. Remove inspection cover at bottom of the clutch housing.

2. Check the adjustment of the clutch. There should be approximately ½” clearance between the top of the bearing cage and the brake plates when the brake plates are positioned against the transmission.

3. Turn flywheel until the adjustment lock is at inspection hole. Remove cap screw and lock.

4. Release clutch by depressing the pedal. The adjusting ring will turn only while the pedal is depressed and the clutch is in the released position.

5. Turn the adjusting ring clockwise to move the bearing cage towards the transmission. Turn the adjusting ring counter clockwise to move the bearing cage towards the flywheel.

6. After approximately ½” clearance is achieved, replace the adjustment lock. This observation must be made while the clutch is in the engaged (pedal up) position.

7. On original installation, adjust the pedal linkage to insure approximately, 1-1/2” of free play on the pedal and approximately 1/8” between the yoke and the wear pads. All future adjustments should be made on the clutch adjusting ring and not on the pedal linkage.

MAINTENANCE TIPS

1. Lubricate the clutch release bearing at each chassis lubrication period, using a high temperature grease. Do not over grease as the excess will find its way to the clutch friction material.

2. Adjust the clutch before the pedal clearance has disappeared. Failure to do this will result in slippage, and an adjustment may not help.

3. If the clutch is hydraulically assisted, make sure the slave and master cylinder are functioning properly.

SERVICE SUGGESTIONS

When replacing the clutch, think in terms of the “total installation”. Failure to replace other worn or damaged components in the clutch system may affect the performance of the replacement clutch you are about to install and may result in a dissatisfied customer. Warranty evaluation will take into account the following clutch related areas.

1. Resurface the flywheel. There is no such thing as an “OK”, used flywheel.

2. Replace the pilot bearing.

3. Replace and properly align the drive lugs in a pot type flywheel, where applicable.

4. Install a new clutch brake where applicable.

5. Check the clutch release fork for wear. No more than .010” allowed on either side. The release fork and shaft assembly must be true to the clutch bearing housing assembly, or proper release may not be achieved.

6. Check the half shafts for wear, as well as the bushings.

7. Look for the telltale rivulet of oil at the bottom of the flywheel housing.

8. Check the splines on the input shaft. If they are worn, the discs may not slide freely.

9. Check flywheel and clutch housing alignment.

10. Check the linkage for wear or separation and lubricate grommets and other potential friction points.

TAKING A FEW EXTRA MINUTES TO CHECK THESE ITEMS WILL HELP ENSURE A PROLONGED, TROUBLE FREE CLUTCH LIFE.
 

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