ALL-MAKES HEAVY-DUTY CLUTCHES

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2 ALL-MAKES HEAVY-DUTY CLUTCHES Alliance Truck Parts has over 30 product lines that serve the commercial transportation industry with reliable new and remanufactured parts and accessories for all makes and all models 1 to keep trucks and buses on the road. All Alliance Truck Parts meet or exceed OES specifications for quality, fit and finish and are backed by a nationwide warranty 2, which means you don t have to trade quality for price.

3 ALL-MAKES HEAVY-DUTY CLUTCHES Illustrations and photographs used in this catalog may vary slightly from the actual product. Prototype samples are sometimes used for photography. The production parts may vary slightly. Availability of products shown in this catalog is subject to change without notice.

4 PARTS NUMBERING SYSTEM PARTS NUMBERING SYSTEM The Alliance Truck Parts numbering system is set up systematically: Example ABP N EZ. PARTS NUMBERING SYSTEM All parts numbers in this program contain the prefix ABP and N25 (the company assigned code for this program). The number following the N refers to the part segment and is different for each. The last six digits are assigned based on part and design. All parts in the catalog are set up with an Alliance Truck Parts number. In the back of this catalog you will find an extensive cross-reference list. This will help link another manufacturer s part to an Alliance ABP number.

5 WARRANTY WARRANTY Alliance truck parts are backed by a 1-year/unlimited-mile standard warranty. WARRANTY

6 NOTES

7 TABLE OF CONTENTS 1 ANGLE SPRING CLUTCHES PAGE 2 HEAVY-DUTY ANGLE SPRING CLUTCHES...3 MEDIUM-DUTY ANGLE SPRING CLUTCHES EASY ASSIST CLUTCHES HEAVY-DUTY EASY ASSIST CLUTCHES MEDIUM-DUTY EASY ASSIST CLUTCHES...10 INSTALLATION & MAINTENANCE INSTALLATION & MAINTENANCE CROSS-REFERENCE PAGE 6 PAGE 12 PAGE 18 CROSS-REFERENCE TABLE OF CONTENTS

8 1 NOTES

9 ANGLE SPRING CLUTCHES 1 2

ANGLE SPRING CLUTCHES FEATURES & BENEFITS 1 HEAVY-DUTY ANGLE SPRING CLUTCHES SPECIFICATIONS Reliable lock-strap adjustment mechanism, which enables trouble-free clutch adjustments Velvet Touch

10 ANGLE SPRING CLUTCHES FEATURES & BENEFITS 1 HEAVY-DUTY ANGLE SPRING CLUTCHES SPECIFICATIONS Reliable lock-strap adjustment mechanism, which enables trouble-free clutch adjustments Velvet Touch ceramic facing, an aftermarket industry standard Damper package to absorb engine vibration Constant plate load and isolated pressure springs for smooth performance FLYWHEEL BORE 8.5 TORQUE RATING NO. OF DISCS 2 NO. OF FACINGS 4 DISC TYPE NO. OF DAMPER SPRINGS 10 ABP N FLYWHEEL BORE 10 TORQUE RATING NO. OF DISCS 2 NO. OF FACINGS 4 DISC TYPE NO. OF DAMPER SPRINGS 7 1,650 lb-ft Dampened ceramic facings with free travel 1,850 lb-ft Dampened ceramic facings with two coaxial springs 3

ANGLE SPRING CLUTCHES SPECIFICATIONS ABP N25 14620SB FLYWHEEL BORE TORQUE RATING

OF DAMPER SPRINGS 8 ABP N25 14860SB FLYWHEEL BORE TORQUE RATING NO.

OF DAMPER SPRINGS 7+1 ABP N25 14860ST FLYWHEEL BORE TORQUE RATING NO.

OF FACINGS DISC TYPE Pot Style 620 lb-ft 3 Super Buttons (3SB) Dampened ceramic

11 ANGLE SPRING CLUTCHES SPECIFICATIONS ABP N SB FLYWHEEL BORE TORQUE RATING NO. OF DISCS 1 NO. OF FACINGS DISC TYPE NO. OF DAMPER SPRINGS 8 ABP N SB FLYWHEEL BORE TORQUE RATING NO. OF DISCS 2 NO. OF FACINGS DISC TYPE NO. OF DAMPER SPRINGS 7+1 ABP N ST FLYWHEEL BORE TORQUE RATING NO. OF DISCS 2 NO. OF FACINGS DISC TYPE Pot Style 620 lb-ft 3 Super Buttons (3SB) Dampened ceramic facing, coaxial, free travel Pot Style 860 lb-ft 3 Super Buttons (3SB) Dampened ceramic facing, coaxial, low rate Pot Style 860 lb-ft 3 Trap NO. OF DAMPER SPRINGS 7+1 Dampened ceramic facing, coaxial, low rate 1 MEDIUM-DUTY ANGLE SPRING CLUTCHES 4

12 5 NOTES

13 EASY ASSIST CLUTCHES 2 6

EASY ASSIST CLUTCHES FEATURES & BENEFITS 2 HEAVY-DUTY EASY ASSIST CLUTCHES SPECIFICATIONS Reliable lock-strap adjustment mechanism, which enables trouble-free clutch adjustments Velvet Touch ceramic

14 EASY ASSIST CLUTCHES FEATURES & BENEFITS 2 HEAVY-DUTY EASY ASSIST CLUTCHES SPECIFICATIONS Reliable lock-strap adjustment mechanism, which enables trouble-free clutch adjustments Velvet Touch ceramic facing, an aftermarket industry standard Damper package to absorb engine vibration Contain assist springs to help reduce pedal effort Pedal effort decrease of 35% compared to Angle Spring design FLYWHEEL BORE 8.5 TORQUE RATING DISCS 2 FACINGS 4 DISC TYPE DAMPER SPRINGS 10 ABP N EZ FLYWHEEL BORE 10 TORQUE RATING DISCS 2 FACINGS 4 DISC TYPE DAMPER SPRINGS 7 1,650 lb-ft Dampened ceramic facings with free travel 1,850 lb-ft Dampened ceramic facings with two coaxial springs ABP N EZ FLYWHEEL BORE 10 TORQUE RATING DISCS 2 FACINGS 4 DISC TYPE DAMPER SPRINGS 7 2,050 lb-ft Dampened ceramic facings with two coaxial springs 7

15 EASY ASSIST CLUTCHES SPECIFICATIONS FLYWHEEL BORE 7 TORQUE RATING DISCS 2 FACINGS DISC TYPE DAMPER SPRINGS 8 CO FLYWHEEL BORE 8.5 TORQUE RATING DISCS 2 FACINGS DISC TYPE DAMPER SPRINGS 10 ABP N EZ FLYWHEEL BORE 10 TORQUE RATING DISCS 2 FACINGS DISC TYPE DAMPER SPRINGS 7 1,400 lb-ft 4 Super Buttons (4SB) Dampened ceramic facing, coaxial, free travel 1,650 lb-ft 4 Super Buttons (4SB) Dampened ceramic facings with free travel 1,700 lb-ft 4 Super Buttons (4SB) Dampened ceramic facing 2 HEAVY-DUTY EASY ASSIST CLUTCHES ABP N EZ6SB FLYWHEEL BORE 10 TORQUE RATING 1,860 lb-ft DISCS 2 FACINGS 6 Super Buttons (6SB) DISC TYPE Dampened ceramic facing, coaxial DAMPER SPRINGS 7 8

16 EASY ASSIST CLUTCHES SPECIFICATIONS 2 HEAVY-DUTY EASY ASSIST CLUTCHES ABP N EZ6SB FLYWHEEL BORE 10 TORQUE RATING 2,050 lb-ft DISCS 2 FACINGS 6 Super Buttons (6SB) DISC TYPE Dampened ceramic facing, coaxial DAMPER SPRINGS 7 9

17 EASY ASSIST CLUTCHES SPECIFICATIONS ABP N SB FLYWHEEL BORE TORQUE RATING NO. OF DISCS 2 NO. OF FACINGS DISC TYPE NO. OF DAMPER SPRINGS 8 Pot Style 1,400 lb-ft 4 Super Buttons (4SB) Dampened ceramic facing, coaxial, free travel 2 MEDIUM-DUTY EASY ASSIST CLUTCHES 10

18 11 NOTES

19 INSTALLATION & MAINTENANCE 3 12

20 INSTALLATION & MAINTENANCE PRE-INSTALLATION TIPS 3 INSTALLATION & MAINTENANCE Inspect the transmission front bearing cap for wear. Replace if the bearing cap is worn Clean the transmission input shaft and inspect for wear and nicks Check the splines for twist: - Take a driven disc and place it on input shaft, then slide the full length of the splines - If the disc hangs up on the splines, replace the transmission input shaft Pilot bearing installation - Inspect the pilot on the end of the input shaft for wear. Replace the input shaft if worn - Check to see if the pilot bearing will fit onto transmission input shaft prior to installing it into the flywheel Release fork/cross-shafts and bushings - Inspect the release fork for wear and replace if signs of wear are present - Replace clutch housing cross-shafts and bushings INSTALLATION INSTRUCTIONS 1 MEASURE ENGINE FLYWHEEL HOUSING AND FLYWHEEL Engine flywheel housing and flywheel must meet these specifications or there will be premature clutch wear. Remove the old pilot bearing. All gauge contact surfaces must be clean and dry. Use a dial indicator and check the following: Flywheel Face Runout 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.008" (.20 mm). 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.005" (.13 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.008" (.20 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.008" (.20 mm). 13

21 INSTALLATION & MAINTENANCE INSTALLATION INSTRUCTIONS 2 INSTALL CLUTCH TO FLYWHEEL For 15.5 clutch only: 3 1 Measure the flywheel bore. Verify that the damper will fit into the flywheel bore. 7" (8-spring) 8.5" (10-spring) 10" (7-spring) 2 Insert the aligning tool through bearing Install the disc onto aligning tool. Follow the orientation instructions on the disc. 7 Install the lock washers and mounting bolts (7/16" x 14 UNC x 2 1/4" grade 5) finger tight. Replace studs with lockwashers and bolts Install the intermediate plate into slots on the clutch cover. Flywheel side must face the flywheel. 8 5 Progressively tighten mounting bolts in a crisscross pattern starting with a lower bolt. Torque to lb-ft (54 68 N m). Install the second disc onto aligning tool. Follow the orientation instructions on the disc. 6 Install two 7/6" x 14 UNC x 5" studs into upper mounting holes. Install assembled clutch. INSTALLATION & MAINTENANCE 9 Remove 4 10 Remove the shipping aligning tool. bolts. CAUTION: An assembled clutch weighs about 150 lb (68 kg). Avoid the risk of injury. Use proper equipment when lifting a clutch. 14

22 INSTALLATION & MAINTENANCE INSTALLATION INSTRUCTIONS 3 INSTALLATION & MAINTENANCE 3 INSTALL TRANSMISSION Check the transmission for wear. Replace any worn components. Transmission Bearing Retainer Cap A worn/rough bearing retainer cap may cause the clutch brake to wear prematurely. Release Yoke Worn fingers can cause bushing wear and yoke interference when the pedal is down. 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 Wear (roughness) can reduce sleeve bushing life and cause it to come out. Fasten Transmission to Flywheel Housing Input Shaft Splines Any wear on the splines will prevent the driven discs from sliding freely, causing poor clutch release (clutch drag). Slide the discs full length of shaft to check for twisted shaft splines. Clutch Brake Replace. Measure Input Shaft Length should be 8.657" ( mm) nominal, and not greater than 8.71" ( mm). Ref SAE handbook 4: Replace the transmission bearing retainer cap if length is greater than 8.71" ( mm). 1 Put the transmission in gear. Be sure new clutch brake has been installed. 2 Make sure that the yoke fingers remain in the up position until they are over the release bearing housing. 3 Position the transmission so it is square to and aligned with the engine. 4 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. 5 Install the mounting bolts and torque to OEM specs. 15

23 INSTALLATION & MAINTENANCE INSTALLATION INSTRUCTIONS 4 SET UP AND LUBRICATE Adjust Bearing Position Verify Clutch Brake Squeeze Verify Free-Play 3 1 Measure the distance between the release bearing and the clutch brake. The correct distance should be.500" -.560" ( mm). If correct go to Step 3. Release bearing.500".560" ( mm) Transmission Clutch brake 2 To change bearing position, you must internally adjust the clutch. Push and hold the pedal down when adjusting. Remove the lockstrap, then rotate adjusting lugs left to move bearing toward transmission. Replace the lockstrap. 3 4 Insert.010" (.25 mm) feeler gauge between the release bearing and the clutch brake. Press the pedal down to clamp the gauge. If the gauge does not clamp, adjust the linkage to achieve clutch brake squeeze, then recheck Step 3. Release bearing Feeler gauge Clutch brake Slowly let up on the pedal and check the pedal position at the moment the gauge can be removed. 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.) 5 Check the distance between the yoke tips and bearing wear pads. This distance should be 1/8" (3.2 mm). Yoke tips Bearing wear pads 6 Do not change the bearing position. To change the yoke finger and bearing wear pads clearance, adjust the upper pedal stop to raise or lower the pedal in the cab. Upper pedal stop 1/8" (3.2 mm) INSTALLATION & MAINTENANCE 1/2" 1" ( mm) Lockstrap Adjusting Lug Lubricate Use a lithium soap-based grease with a minimum of 325 F (163 C) operating range meeting N.L.G.I. grade 1 or 2 specs. Apply ample grease that visibly exits the opening and contacts the transmission shaft. This will lube the clutch brake when the pedal is pressed. 7 Apply grease to the input shaft and yoke fingers. 8 Apply grease to the cross-shaft bushings and linkage pivot points. Transmission 9 Grease the release bearing. 16

24 INSTALLATION & MAINTENANCE MAINTENANCE TIPS 3 INSTALLATION & MAINTENANCE 1 LUBRICATION Use NL GI #2 lithium complex Grease every 20,000 miles or two months for Line Haul Grease every 250 hours or one month for Severe Service (Vocational) 2 CLUTCH ADJUSTMENT Adjust the clutch release bearing to compensate for disc wear Maintain between the bearing and clutch brake Maintain.125 between the release fork and release bearing wear pads 17

25 CROSS-REFERENCE 4 18

26 CROSS-REFERENCE ACE HALDEX COMP. P/N ALLIANCE P/N COMP. P/N ALLIANCE P/N B EZ CB EZ CB0 EZ CB ABP N ST ABP N SB ABP N SB N N CE N C ABP N SB ABP N SB CO CROSS-REFERENCE EZ B EZ H EZ EZ B EZ B COMP. P/N SP B ABP N SB ABP N ABP N EZ ABP N EZ6SB ABP N EZ ABP N EZ6SB CO ABP N EZ CO EATON ALLIANCE P/N ABP N SB SP B SP SP B SP AM SP AM SP AM SP AM SP AM ABP N ST ABP N SB CO ABP N EZ ABP N EZ6SB ABP N EZ ABP N EZ6SB ABP N EZ N N CE N C N N C N N C N TM N TM N N C RC018CX RC018EZCX RC018EZX RC018X ABP N SB ABP N SB ABP N SB CO CO ABP N ABP N EZ ABP N EZ6SB ABP N EZ ABP N EZ6SB ABP N EZ ABP N EZ CO CO CO CO RC390CZ ABP N SB HALDEX RC390EZCX ABP N SB COMP. P/N ALLIANCE P/N RC597CX N C ABP N SB RC597DCX N CO RC597EZCX RC597EZDCX N RC700EZX ABP N EZ N C RC700X ABP N EZ N N CE ABP N ST ABP N ST RC892520EZX ABP N ABP N EZ ABP N EZ6SB The above cross-reference was determined using manufacturers specifications for torque rating and flywheel bore size. 19

27 CROSS-REFERENCE HALDEX MID-AMERICA COMP. P/N ALLIANCE P/N COMP. P/N ALLIANCE P/N RC892525EZX COMP. P/N ABP N EZ ABP N EZ6SB IATCO ALLIANCE P/N MU DSCB MU DSCB MU DSCB MU DSCB ABP N SB ABP N SB ABP N ST 4 NMU NMU NMU A NMU A NMU NMU NMU NMU NMU ABP N SB ABP N SB ABP N ST ABP N SB ABP N SB ABP N EZ ABP N ABP N EZ ABP N EZ6SB ABP N EZ ABP N EZ6SB CO MU DSCB MU SB-7 MU SB-10 MU DSCB MU DSCB MU SB-7 MU SB-10 MU SB-7 ABP N SB ABP N EZ CO ABP N SB ABP N EZ ABP N ABP N EZ ABP N EZ6SB CO ABP N EZ ABP N EZ6SB CROSS-REFERENCE NMU NMU NMU NMU CO ABP N ABP N EZ ABP N EZ6SB ABP N EZ ABP N EZ6SB CO COMP. P/N CL CL CL CL CL TRP ALLIANCE P/N ABP N SB CO ABP N ST COMP. P/N MERITOR ALLIANCE P/N CL CL ABP N ST ABP N SB R15010 R R R R ABP N ABP N EZ ABP N ABP N EZ ABP N ABP N EZ CL CL CL CL CL CL ABP N SB ABP N SB ABP N EZ ABP N SB CO R ABP N ABP N EZ CL ABP N EZ ABP N EZ6SB R ABP N EZ CL ABP N EZ The above cross-reference was determined using manufacturers specifications for torque rating and flywheel bore size. 20

28 CROSS-REFERENCE 4 COMP. P/N CL CL CL TRP ALLIANCE P/N CO ABP N EZ ABP N EZ6SB CROSS-REFERENCE CL COMP. P/N M F5 M F5 SP-AN G5 SP-AN G5 SP-AN G5 SP-AN W5 SP-AN G5-NSR ABP N EZ UNIQUE ALLIANCE P/N ABP N SB ABP N ST ABP N SB CO ABP N EZ ABP N ABP N EZ ABP N EZ6SB ABP N SB The above cross-reference was determined using manufacturers specifications for torque rating and flywheel bore size. 21

29 NOTES 22

30 Find your nearest dealer at alliancetruckparts.com DTNA/PSM-M-981. Specifications are subject to change without notice. Copyright Daimler Trucks North America LLC. All rights reserved. Alliance Truck Parts is a brand of Daimler Trucks North America LLC, a Daimler company. 1 For nearly all heavy-duty truck makes and models. 2 See warranty for complete details and limitations.

Clutch Installation Guide

Clutch Installation Guide 0 STOP! READ CAREFULLY BEFORE INSTALLING CLUTCH This clutch must be installed by a qualified installer. Improper installation or failure to replace or resurface the flywheel,