4 Identification P/N & S/N are located on the machined surface of clutch housing Sachs Example: (12 Digits) & S/N C These numbers are required if a warranty claim should occur
5 Release bearing changes
6 Tools Required Tools, Parts, Equipment (A) Guide pins 7/16 x 5 (B) Clutch Brake gap gage (C) 1/8 Fork gap gage (D) Torque Wrench w/ 10 inch extension & 6mm Allen Head socket (E) Disc hub alignment tool (single shaft or as part of clutch jack Note: Tools A-E are available through various tool retailers Hook Tool (required for hydraulic actuation systems/ optional for mechanical linkage actuation systems) Part Number from ZF Sachs)
7 Installation Important Notes! Do not tamper with bolts as shown Use guide pins for hanging of clutch and for guidance of the transmission to flywheel-housing
8 Installation Before Proceeding Ensure that all mating components of the clutch and the entire clutch actuation system are inspected and replace worn components as needed Check: Pilot bearing, Release Yoke, Cross Shaft Bushings, Input Shaft, Input Shaft Bearing Retainer, Clutch Brake, Linkage/Hydraulic Release System Check the runout on the outer surface of the flywheel, the bore of the pilot bearing, and the outer surface and bore of the flywheel housing as well as the crank shaft end play to verify that they meet specs Recommend replacing pilot bearing and clutch brake when installing new clutch
9 Runout of Pilot Bearing Bore Push the flywheel toward the engine so that the end play of the crankshaft is not measured. 2. Install a dial indicator so that the base of the indicator is on the mounting surface of the flywheel housing. Place the tip of the dial indicator against the outer surface of the bore for the pilot bearing.. 3. Set the dial indicator on the zero mark.
10 Runout of Pilot Bearing Bore NOTE: Do not use the starter to move the flywheel. Rotate the crankshaft with the correct size of socket on the front pulley. If the front pulley is difficult to turn, use a spanner wrench on the teeth of the flywheel to move the flywheel. 4. Manually turn the crankshaft one revolution in the direction of engine rotation. 5. Record the reading on the dial indicator. The maximum allowable runout for the surface of the bore of the pilot bearing is inch (0.127 mm). If the runout is more than inch (0.127 mm), service the crankshaft as required. Refer to the vehicle or engine manufacturer s procedure.
11 Crankshaft End Play 1. Push the flywheel toward the engine. 2. Install a dial indicator so that the base of the indicator is on the flywheel housing. Place the tip of the dial indicator against the hub of the flywheel. 3. Set the dial indicator on the zero mark. 4. Pull the flywheel away from the engine. 5. Record the reading on the dial indicator. Check the reading against the specification of the manufacturer of the engine or vehicle. Service the crankshaft as required.
12 Runout - Flywheel Housing Outer Surface 1. Check the runout on the outer surface of the flywheel housing. 2. Push the flywheel toward the engine so that the end play of the crankshaft is not measured. 3. Install a dial indicator so that the base of the indicator is on the flywheel. Place the tip of the indicator against the mounting surface of the flywheel housing.. 4. Set the dial indicator on the zero mark. NOTE: Do not use the starter to move the flywheel. Rotate the crankshaft with the correct size of socket on the front pulley. If the front pulley is difficult to turn, use a spanner wrench on the teeth of the flywheel to move the flywheel. 5. Manually turn the crankshaft one revolution in the direction of engine rotation. 6. Record the reading on the dial indicator. Typically, the maximum allowable runout for the outer surface of the flywheel housing is0.008-inch (0.203 mm). 7. If the runout on the outer surface of the flywheel housing is more than inch (0.203 mm), service the flywheel housing as required. Refer to the vehicle manufacturer s procedure.
13 Runout - Flywheel Inner Bore 1. Check the runout on the inner bore of the flywheel housing. 2. Push the flywheel toward the engine so that the end play of the crankshaft is not measured. 3. Install a dial indicator so that the base of the indicator is over the center of the flywheel. Place the tip of the indicator against the inner bore of the flywheel housing. 4. Set the dial indicator on the zero mark. NOTE: Do not use the starter to move the flywheel. Rotate the crankshaft with the correct size of socket on the front pulley. If the front pulley is difficult to turn, use a spanner wrench on the teeth of the flywheel to move the flywheel. 5. Manually turn the crankshaft one revolution in the direction of engine rotation. 6. Record the reading on the dial indicator. The maximum allowable runout for the inner bore of the flywheel housing is inch (0.203 mm). 7. If the runout of the inner bore of the flywheel housing is more than inch (0.203 mm), service the flywheel as required. Refer to the vehicle or engine manufacturer s procedure.
14 Input shaft wear Inspect input shaft for wear Inspect the splines on the input shaft. Make sure the splines are not worn or damaged. Inspect the area of travel for the release bearing for damage. Use an emery cloth to remove small scratches from the input shaft. Replace input shafts that are worn or damaged. Any wear or damage on the input shaft causes the clutch not to operate correctly. If in doubt, Replace!
15 Cross Shaft and Fork Inspection Inspect the shaft and the release fork. Make sure the release fork is straight and the tips of the fork are not worn or damaged. Replace forks that are worn or damaged. Make sure the cross shafts rotate freely in the transmission housing. Make sure the shaft does not have any excessive radial (fore and aft) movement in the housing. If used, inspect the bushings for the shaft in the housing. Replace bushings and shafts that are worn or damaged. Inspect linkage per OEM specifications.
16 Input shaft bearing retainer wear Inspect for wear Measure distance as shown in picture Replace if out of spec
17 Installation Ensure that the maximum torque rating of the clutch fits to the engine peak torque rating! Verify flywheel bore opening is 10.1 If flywheel is resurfaced, ensure a clearance for the clutch disc damper by checking that the depth of crankshaft bolts to Flywheel surface is a minimum of 0.47
18 Installation Check that disc slides freely on input shaft Observe Flywheel disc orientation (see inscription on clutch disc plate)
19 Installation Insert guide studs to Flywheel at positions #4 and #8 Insert alignment tool through clutch into pilot bearing Place clutch on guide studs Note: Check that alignment tool is all the way into the pilot bearing!
20 Installation Hand tighten bolts #1, 2, 3, 5, 6, and 7 Remove guide studs and hand tighten #4 and 8 Tighten the (8) cover bolts in criss-cross pattern in the order as shown in the picture and torque to 50 ft-lbs Do not remove alignment tool at this stage!
21 Installation Remove (4) shipping bolts (yellow tags) 7/ Now remove the alignment tool
22 Installation Use guide pins installed in the flywheel housing at 10 & 2 o clock to align transmission during installation to align engine and transmission housing in order to keep input shaft centered during insertion into clutch disc hubs. Note: To ease transmission installation, maintain release bearing alignment!
23 Installation Check that engine and transmission are aligned Note: The transmission should slide without force into the disc splines and the pilot bearing Excessive force installing the transmission may cause damage to the clutch!
24 Transmission Installation Place the transmission in high range and direct gear. This will allow the technician to turn the output yoke transmission more easily. Move the transmission forward to the engine so the input shaft is inserted into the release bearing. Rotate the release fork fingers into the normal position over the bearing as soon as space permits. Applying slight force to the transmission, rotate the transmission output shaft (transmission has to be in gear) until the flywheel housing mates to the clutch housing. This ensures that the input shaft aligns with the hub splines of the clutch disc assemblies. Caution - Never use the transmission mounting bolts to pull the transmission assembly to the clutch housing. Damage can occur.
25 Bearing Adjustment Actuate clutch several times to seat bearing, before doing the following: First, check clutch brake gap is at ± If out of specification, reference the following slides
26 Tools Required Tools, Parts, Equipment A 6mm Allen head socket with 10 inch extension B Standard 1/2" drive torque wrench C Hook Tool (required for hydraulic actuation systems/optional for mechanical linkage actuation systems) Part Number from ZF Sachs
27 Clutch Adjustment *Note: Use the Hook Tool to rotate the Lock Collar so the Lock Bolt is accessible through the inspection window Fully depress the clutch pedal to the floor of the cab and secure pedal in this position This will make the Lock Bolt accessible through the bell housing inspection hole as shown in the next step
28 Clutch Adjustment Use the following procedures to achieve a Clutch Brake Gap of 0.530" Loosen the Lock bolt on the Lock Collar DO NOT remove bolt completely only loosen in Lock Collar by approximately 2 turns Once the Lock bolt is loose, release the clutch pedal. Failure to release the clutch pedal will make adjustment impossible.
29 Clutch Adjustment Use the following procedures to achieve a Clutch Brake Gap of 0.530" ±0.030 Turn the Adjusting Nut (which is attached to the threaded sleeve), in the appropriate direction (in relation to the flywheel): Clockwise to increase the clutch brake gap Counterclockwise to decrease the clutch brake gap Notes: The adjusting nut is located directly next to the release bearing on the threaded sleeve With a mechanical linkage, a screwdriver can be used to push on either side of the nut to rotate it in the appropriate direction (as shown in the photo to the right) With a hydraulic actuation system, a hook tool (Part Number from ZF Sachs) is required to push or pull on the adjusting nut due to a partially obstructed view
30 Clutch Adjustment Fully depress the clutch pedal Use a Torque Wrench to Torque the Lock Bolt to: lb-ft ( Nm) Note: Failure to apply required torque will lead to failures in the field and denial of warranty.
31 Fork Gap For Mechanical Linkage only Check linkage fork gap is 1/8 If out of specification, adjust linkage rod Check clutch brake squeeze For Hydraulic Actuation only No free-play adjustment necessary Check Clutch Brake Squeeze (both Mechanical & Hydraulic Systems) Fully depress clutch pedal and verify that the clutch release bearing contacts clutch brake
32 Greasing Bearing Final step is to prepare Release Bearing for initial in-service period. Make sure that sufficient grease is present, such that it will begin to purge from Housing as additional grease is added. This incidental purge is essential to keep Input Shaft to Bushing sleeve interface properly lubricated. Do Not Overgrease! High temp multi-purpose wheel bearing grease (Lithium Complex, NLGI Grade #3) is recommended.
33 Final Test Final System Functional Test 1. Place transmission in neutral 2. Start Vehicle engine 3. Raise engine speed to rpm 4. Actuate the clutch pedal 5-7 times 5. Turn Engine off 6. Recheck clutch brake to bearing clearance, re-adjust clutch brake and release fork if necessary. Test Drive After completion of a successful clutch installation, a short vehicle test drive should be completed to break in and seat the flywheel and pressure plate friction surfaces. Failure to do so may result in excessive initial slipping and overheating of the clutch assembly causing damage to the clutch disc(s) friction material.
34 Removal Make sure to reinstall shipping bolts before removal If removed before installing bolts, clutch is not usable and warranty is voided Insert alignment tool through the clutch all the way into the pilot bearing Insert (4) shipping bolts (locations as shown by the arrows in top picture) and hand tighten Then, turn shipping bolts an additional 1/2 turn (180 degrees rotation) with hand wrench Note: DO NOT USE IMPACT WRENCH as tightening beyond the recommended amount can damage clutch release mechanism! Do not use an air gun!
35 Adjusting the Clutch Linkage The following is general information on adjusting the clutch linkage. For specific adjustment procedures of the clutch linkage, refer to the procedure of the manufacturer of the vehicle. There are four adjustments for correct clutch linkage adjustment. Pedal Height. Total Pedal Travel. Clutch Brake Squeeze (Non-Synchronized Transmission Only). Free Travel. The free travel adjustment is done after all the other adjustments are done.
36 Clutch Pedal The free travel makes sure that the release bearing does not touch the release fork during vehicle operation. As normal facing wear occurs, the release bearing moves toward the engine and reduces the clearance between the release bearing and the fork which also reduces the free travel of the clutch pedal.
37 Clutch Brake Squeeze Clutch Brake Squeeze (Non-Synchronized Transmission Only) Remove the cover for the inspection hole on the clutch housing. Adjust the linkage so that the release bearing housing touches the clutch brake when the clutch pedal is typically 1.0-inch (25 mm) from the end of pedal travel as defined by the manufacturer of the vehicle. Clutch brake squeeze is usually adjusted somewhere on the linkage between the release lever at the bell housing and the clutch pedal.
38 Clutch Brake Squeeze To check if clutch brake squeeze is within spec perform the following check: A feel gauge must fit snugly between the release bearing and the clutch brake when the clutch pedal is fully depressed. Warning: If no brake squeeze is present, clutch drag will occur and may result in excessive initial slipping and overheating of the clutch assembly causing damage to the clutch disc(s) friction material.
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