Clutch Course Part 3 Flashcards
Clutch Installation Step 7
Install lock washers and 7/16x14x2 ¼ grade 8 finger tight.
WARNING: Finger tighten only at this point.
Clutch Installation Step 8
Now that all 8 fasteners are finger tight start out in a crisscross pattern and torque to 40-50 lb ft.
WARNING: Failure to tighten in crisscross pattern can result in improper piloting of the clutch and cause damage. THIS WILL VOID WARRANTY.
Clutch Brake details
If the clutch brake was removed, install the new clutch brake on the transmission input shaft sliding it tight against the input shaft bearing cap.
Note: Soak clutch brake assembly in Dexron ATF for 10 min. prior to install.
Two piece brake torque spec. 181182106
Be sure the release yoke clears the release bearing and is rotated over the wear pads as the transmission is moved forward.
Align the input shaft splines with the clutch disc splines by turning the transmission output shaft. Use care to avoid springing the drive discs when the transmission is being installed. Do not force the transmission into the clutch or flywheel housing if it does not enter freely. Do not let the transmission drop or hang unsupported in the driven discs. This can damage the clutch assembly. Push the transmission slowly forward until the clutch housing pilot flange enters the flywheel housing pilot bore.
Transmission Installation
After the engine reaches operating temperature, stop and recheck the transmission level. The fluid must be at the bottom of the fill hole or in window of the sight glass. Lower the hood and remove the chocks from the tires.
Warnings: Some transmissions have cooler lines that attach with quick disconnect fittings and must be installed using a specific technique. We have had a few roadside transmission failures due to excessive water in the air tanks, thus creating issues with the range cylinder. Along with this being the drivers responsibility, it is a key part of our PM program. Please ensure our tech’s are draining the air tanks at all PM services.
In vehicle resetting procedure
If the cam tab does not move there is not enough release bearing travel to allow cams to separate. In this case, Put Transmission jack back under transmission and loosen the transmission and install ½ inch spacers between the flywheel housing and bell housing, push the clutch pedal to the floor while someone pushes the cam tab to the new position. Once the tab is in the raised area at the new position, release the clutch pedal and remove the spacers. Torque the transmission mounting bolts. Rotate engine to access (4) shipping bolts. Install and progressively tighten until they bottom out.
If the release bearing travel is still greater than 0.590 between the clutch brake and the release bearing repeat the 2 steps on previous slide. For mechanical linkages, adjust the clutch linkage to achieve 1/8” clearance between the release yoke and release bearing. Verify proper clutch brake squeeze.
Clutch Installation Step 9
Remove four yellow shipping bolts in a crisscross pattern
Clutch Installation Step 10
Remove alignment tool
Clutch Installation Step 11
Install brass fitting into grease port on the road side of release bearing housing using a Weatherhead socket. Tighten hand tight and continue to turn till opening of fitting faces toward 6 o’clock position
Transmission installation
Check for wear on the fingers of the clutch release yoke, release shafts, and release shaft bushings. Replace worn parts as necessary. Shift transmission into gear, so that the transmission input shaft can be rotated during assembly, and line it up with the clutch driven disc hub splines. Roll transmission and jack into alignment behind engine. Raise transmission jack support plate until the flange of the clutch housing is parallel (all the way around) to the flange of the housing. Align transmission input shaft with the hole in the release bearing sleeve.
What should you do if you don’t know your spec?
Look it up.
What is the first step in the in-vehicle resetting procedure?
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.
Example sentence: If the measurement is between 0.490 and 0.590, the solo has set itself correctly.
What should you do if the release bearing travel is less than 0.490?
The solo must be reset. A common cause of this is the transmission was pulled in with the release arm during clutch installation.
What should you do in the out of vehicle resetting procedure?
Center the ram and press downward on the retainer until it comes to a stop. Slide the wear indicator tab to the ‘GOOD’ position and hold it in place with a magnet. Install the four shipping bolts (7/16 x 14 x 1 ¾* UNC, hex head). Progressively tighten (no power tools) the 4 shipping bolts (crisscross pattern) until the face of the pressure plate is 1.75’-1.78’ (44.4-45.2 mm) below the mount.
What should you do until the retainer comes to a stop?
Slide the wear indicator tab to the “GOOD” position and hold it in place with a magnet.
Example: Slide the wear indicator tab to the “GOOD” position.
