mejora continua en instruccion vial del ferodo ambiguo y continuo de energon combinado

8/10/2019 mejora continua en instruccion vial del ferodo ambiguo y continuo de energon combinado

1/68

Heavy-Duty Clutches

Service Manual

CLSM0200

January 2012

Solo Advantage

Easy Pedal Advantage

Value ClutchUltraShift DM

UltraShift PLUS ECA Clutch

More time on the road

TM


2/68


3/68

i

Warnings

Warnings and Cautions

Repair Warnings

The major cause of clutch failure is excessive heat. Excessiveheat generated between the flywheel, driven discs, intermedi-ate plate and pressure plate can cause the metal to flow andthe material to be destroyed. If this occurs, the clutch canburst which can cause property damage, serious bodily injuryor death. In order to prevent clutch failure resulting fromexcessive heat:

1. Do not exceed recommended vehicle loads.

2. The clutch should only be used for the recom-mended applications.

3. Drivers should be properly trained in starting, shift-

ing and operation of the clutch.

4. Drivers should report erratic clutch operation assoon as possible to permit maintenance personnel toinspect, adjust or lubricate as required.

5. Mechanics must be familiar with proper clutchadjustment, linkage adjustment, lubrication andother maintenance troubleshooting procedures out-lined in the Failure Analysis Guide.

When disassembling various assemblies, lay all parts on aclean bench in the same sequence as removed to simplify andreduce the possibility of losing parts.

Since the cost of a new part is generally a small fraction of thecost of downtime and labor, avoid reusing a questionable partthat could lead to additional repairs and expense.

Use of other than recommended tools, parts, and instructionslisted in this manual may place the safety of the service tech-nician or vehicle driver in jeopardy.

The removal and installation procedure described for each

component may vary for your vehicle.

For Solo and Heavy-Duty ECA clutches only, install shippingbolts before removing clutch assembly from the flywheel.

For service information and assistance, call the RoadrangerHelp Desk at 1-800-826-HELP (4357) (Mexico: 01-800-826-HELP (4357). You may also find more information aboutEaton Clutches at www.Roadranger.com.

Every effort has been made to ensure the accuracy of the

information contained in this manual. However, Eaton Corpo-ration makes no warranty, expressed or implied, based on theinformation provided.

IMPORTANT


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ii

Warnings


5/68

iii

Table of Contents

Warnings and CautionsRepair Warnings . . . . . . . . . . . . . . . . . . . . . . i

Solo AdvantageSelf-Adjusting Clutches

Remove Clutch . . . . . . . . . . . . . . . . . . . . 1Install Solo Advantage HD 15.5" Clutch . . . 2

Measure Engine Flywheel Housingand Flywheel . . . . . . . . . . . . . . . . . . . . . . 2Install Clutch to Flywheel. . . . . . . . . . . . . 3Install Transmission . . . . . . . . . . . . . . . . 5Set-up . . . . . . . . . . . . . . . . . . . .. . . . . . 7

Troubleshooting for Solo AdvantageHD15.5" Clutches . . . . . . . . . . . . . . . . . . . . . . . 10

Symptom-Driven Diagnostics . . . . . . . . . 10Too Much Free Pedal or Too MuchClutch Brake . . . . . . . . . . . . . . . . . . . . . . 1

Not Enough Free Pedal or NoClutch Brake . . . . . . . . . . . . . . . . . . . . . . 12

Resetting Procedures . . . . . . . . . . . . . . . . . 13In-Vehicle Reset Procedure . . . . . . . . . . . 13In-Vehicle Resetting Procedure Usingthe Solo Advantage Clutch Reset Tool. . . 14Verify Clutch Brake Squeeze . . . . . . . . . . 15Out-of-Vehicle Reset Procedure for HDECA or Solo Advantage Clutches . . . . . . . 16

Easy Pedal AdvantageManual Adjust Clutches

Install Easy Pedal Advantage & ValueClutch . 17Install Clutch to Flywheel . . . . . . . . . . . . . . . 18Install 15.5" Clutch to Flywheel . . . . . . . . . . . 18Install Transmission. . . . . . . . . . . . . . . . . . . . 20Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

UltraShift DM Heavy Duty ClutchRemove Clutch . . . . . . . . . . . . . . . . . . . . . . . 26UltraShift DM Clutch Install Clutchto Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 28Install Transmission . . . . . . . . . . . . . . . . . . . 29Heavy-Duty UltraShift Clutch Recalibration . . 30

ECA ClutchRemove Clutch . . . . . . . . . . . . . . . . . . . . . . . 32Opening the ECA Clutch. . . . . . . . . . . . . . . . . 3215.5" Heavy-Duty ECA Clutch Installation . . . 35Install Clutch to Flywheel . . . . . . . . . . . . . . . 36Install Transmission . . . . . . . . . . . . . . . . . . . 37Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39ECA Clutch Adjustment . . . . . . . . . . . . . . . . . 40Grease Interval Count Reset . . . . . . . . . . . . . 42

ServiceRanger Procedure . . . . . . . . . . . . . . . .42Operator Triggered Procedure . . . . . . . . . . . .44ECA Clutch In-Vehicle Resetting Procedure . .45Opening the ECA Clutch . . . . . . . . . . . . . . . . .45

Low Capacity Inertia BrakeWear Life Measurement . . . . . . . . . . . . . . . . . 48Transmission Removed . . . . . . . . . . . . . . . . .48Transmission in Chassis. . . . . . . . . . . . . . . . .48

Hydraulic Linkage . . . . . . . . . . . . . . . . . . . . . . .49Verify Linkage System Stroke . . . . . . . . . . . . .49Master Cylinder Installation . . . . . . . . . . . . . .49Transmission Installation . . . . . . . . . . . . . . . .50Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . 51

Solo Advantage Lube Hose AssemblyWith Hydraulic Linkage

Installation Process . . . . . . . . . . . . . . . . . . . .52

General Clutch InformationFunction of a Clutch . . . . . . . . . . . . . . . . . . . .54Neutral Idle Rattle . . . . . . . . . . . . . . . . . . . . . . 54Self-Adjusting Clutches. . . . . . . . . . . . . . . . . .55Clutch Disc Friction Material . . . . . . . . . . . . . .56Clutch Slippage. . . . . . . . . . . . . . . . . . . . . . . .56Clutch Torque Capacity. . . . . . . . . . . . . . . . . .56Clutch Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . 56Driven Disc . . . . . . . . . . . . . . . . . . . . . . . . . . .57Facings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Intermediate Plate. . . . . . . . . . . . . . . . . . . . . .57Positive Separator Pin . . . . . . . . . . . . . . . . .576-Position Kwik-Adjust . . . . . . . . . . . . . . . .57Clutch Brakes . . . . . . . . . . . . . . . . . . . . . . . . .57

Factors that Effect Clutch Performance. . . . .58When to Inspect the Clutch. . . . . . . . . . . . . . .59

Preventative Maintenance OverviewInspection for Clutch Life . . . . . . . . . . . . . . . .59Designing a Clutch for a Specific Application .59Preventive Maintenance Overview . . . . . . . . .60Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . .60Recommended Lubrication . . . . . . . . . . . . . .60Lubrication Interval . . . . . . . . . . . . . . . . . . . .60


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iv

Table of Contents


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1


Remove Clutch

(If clutch is to be reinstalled and transmission isstill in vehicle)

Note the position of the wear indicating tab on the clutch. Ifthe tab is near the REPLACE position, the clutch should bereplaced.

1. Locate 4 shipping bolts (7/16" x 14 x 1 3/4" UNC, hexhead). Install them in the 4 cover holes hand tightthen turn one full turn.

2. Support the Clutch during the removal of the 8mounting bolts.

3. Remove the clutch from the flywheel.

Note: Mark the proper position of the discs and interme-diate plate (for reinstallation).

This step will hold the pressure plate separator pins in properposition so the clutch can be reused and will release afterreinstalling.

CAUTION

Shipping Bolts(4) 7/16" x 14 x 1-3/4" UNC

IMPORTANT


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2


Install Solo Advantage Heavy-Duty 15.5" Clutch

Measure Engine Flywheel Housing and Flywheel

Engine flywheel housing and flywheel must meet these specifications or it may result in premature clutch failure. Remove andreplace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheelsurfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch.

Use a dial indicator and check the following:

Pilot Bearing Bore Runout

Flywheel Housing Face Runout

Secure dialindicatorbaseto flywheelhousing face.

Rotate flywheelone revolution.Maximum runout is0.008" (0.20 mm).

1 Positiongauge fingerso that it contactspilot bearing bore.

2

Rotate flywheel onerevolution. Maximumrunout is0.005" (0.13 mm).

3

Secure dial indicatorbase to flywheel nearthe outeredge.

1

Put gauge fingerincontact with face offlywheel housing.

2 3

Flywheel Face Runout

Flywheel Housing I.D. Runout

Secure dial indicatorbase to crankshaft.

1 Put gauge fingeragainst flywheelhousing pilot I.D.

2


3


3

Put gauge fingerincontact with flywheelface nearthe outeredge.

2Secure dial indicatorbase to flywheelhousing face.

1


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3


Install Clutch to Flywheel

Use the EatonClutch SelectorGuide (CLSL1511)to make sure youhave the right clutch.

Anassembled clutch weighsabout 150 lbs(68 kg).

Avoid therisk of i

njur

y. Use p

rope

req

uipme

ntwhenlifting a clutch.

Progressively tightenmounting boltsina crisscrosspatternstarting with thelowerleft bolt (1, 2, 3, 4, 5, 6, 7, 8).Torque to 40-50 lb-ft (54-68 Nm).Failure to do thiscould result inimproperpiloting of the clutchand cause clutch damage.

8

Install lock washersand mountingbolts(7/16" x 14 UNC x 2-1/4"grade 5) fingertight. Replace

studswith lock washersand bolts.

7

Install second disc onto aligningtool. Follow the orientationinstructionsonthe disc.

5

Install intermediate plate into slotsonthe clutch cover. Flywheel sidemust face the flywheel.

4

Install disc onto aligning tool.Follow the orientationinstructionsonthe disc.

3

Insert aligning toolthrough bearing.

2

Note:Wheninstalling clutch to flywheel, positionthe wearindicatorat the bottom of flywheelto ease future clutch servicing.

Install two 7/16" x 14UNC x 5" studsinto uppermounting holes. Installassembled clutch.

6

1

3

4

5

6

7

8 2

IMPORTANT WARNING

Measure the flywheel bore.Use the EatonClutchSelectorGuide to verify thatthe damperwill fit into theflywheel bore.

7.0" (8-spring)

8.5" (10-spring) 10.0" (7-spring and Mack 9-spring)Note: Mack 9-spring forMack and Volvo

engines2007 and neweronly.

1


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4


Install HD Solo Advantage Lube Hose Attachment

Remove thealigning tool.

Remove fouryellowshipping boltsinacrisscrosspattern.

Pin

10

9

Use a six once hammeranda 1/4" flat nose punch tolightly tap the fourseparator

plate pinstoward the flywheel.Only part of the pinshould be visible.If installing Solo Advantage Clutch,proceed toStep 12.

11

14

12 Install brassfitting into greaseport onleft side of release bearinghousing using Weatherhead socket.Tightenhand tight and continue to

turnuntil the opening of the fittingisfacing toward the 6 oclock position.

13 Install lube hose intobrassfitting and tightenuntil hand tight,thenturnanadditional 2 turns.

Lubricate release bearing until

grease p

urge

sfrom

relea

se bea

rin

ghousing. Use NLGI grade 2 or3 Lithiumcomplex grease. Reference Eatonlubricationmanual TCMT0021forspecific instructions.

Note:The example shownisof a Lube Hose Attachmentfora heavy-duty Hydraulic release system.

Note:A-8173 hand hole coverwithgrommet isrequired with HD SoloAdvantage clutch used with hydraulicrelease system.


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5


Install Transmission

Check Transmission for WearReplace any worn components.

IMPORTANT

Do not add lube (neverseizeorgrease) to the input shaftsplines. The discsmust befree to move.

Note: Adjust the linkage until pushingthe pedal downmovesthe bearingagainst the clutch brake. Let up onthepedal and measure the distancebetweenthe bearing and clutch brake(distance should be 0.490"-0.560").

Input Shaft SplinesAny wearonthe splineswillprevent the drivendiscsfromsliding freely, causing poorclutch release (clutch drag).Slide discsfull length of shaft tocheck fortwisted shaft splines.

Clutch BrakeReplace.

Cross Shaft andBushingsExcessive wearat these pointscancauseside loading onthe sleeve bushing,bushing failuresand yoke bridge contactwith the clutch whenthe pedal isdown.

Measure Input ShaftLength should be 8.657" (219.89 mm) nominal, and notgreaterthan8.71" (221.23 mm). Ref. 1990 SAEhandbook 4:36.106. Replace transmissionbearingretainercap if length isgreaterthan8.71" (219.89 mm).

TransmissionBearingRetainerCapA worn/rough bearingretainercap may causethe clutch brake to wearprematurely.

Release YokeWornfingerscancausebushing wearand yokeinterference whenthepedal isdown.

Input Shaft

Wear(roughness) canreduce sleeve bushing lifeand cause it to come out.

CAUTION

Do not use the cross-shaft release lever(ora pipe overit) to pull the transmissionintoitsfinal position. Pulling the bearing too farduring installationcancause anoverstrokecausing the release bearing to move closer

to the trans

miss

ion

(less

than

0.490") withthiscondition. Follow the Out of VehicleResetting Procedure onpage 1.

Do not let the transmissiondrop orhangunsupported inthe drivendiscs. Thiscanbend the discsand the clutch will not releasecausing damage that isnot warrantable.

Do not excessively force the transmissioninto the clutch assembly orenginehousing. Thiswill cause damage to thesplinesof the reardisc hub that isnotwarrantable. If the discsdo not slide freely

in

the in

pu

tshaft, i

nvestigate the ca

use ofthe problem and make any necessary

changes. If the discsdo not slide freely, theclutch will not release and the transmissionwill grind going into gear.


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6


Fasten Transmission to Flywheel Housing

1 Put transmissioningear.Make sure new clutchbrake hasbeeninstalled.

3 Positiontransmissionsoit issquare to andaligned with engine.

4 Mesh splinesby movingtransmissionforward androtating the output shaft.

2 Make sure that the yokefingersremaininthe uppositionuntil they are over

therelea

se bea

ring ho

using.

5 Install mounting boltsandtorque to OEM specs. Ifinstalling Solo Advantageclutch, proceed to Step 6.

Do not let the transmissiondrop orhang unsupported inthe drivendiscs. Thiscancausethe discsto become distortedand the clutch to not release.

WARNING

Do not pull onrelease arm to installtransmission. Thiswill cause theclutch to overadjust.

Do not force transmissionagainstclutch with yoke fingersinthe UPposition. Thiswill break the castwebbing of the clutch causingdamage that isnot warrantable.

Do not use excessive force. If itdoesnot enterfreely, investigatethe cause of problem and makeany necessary changes.

CAUTION

IMPORTANT

Do not add lube (neverseize orgrease) to the input shaft splines.The discsmust be free to move.

6 Install hand hold coverA-8173 with grommetpositioned toward rearofhand hold opening intheclutch housing. Secure thehand hole coverwith two5/16" x 18 x 1/2" long bolts.

7 Insert plug into hole inthe upperleft side of the clutch housingwhere the horizontal lube hoseisutilized. (Image not shown)

Note:If the lube hose assemblyshould need servicing it canbereplaced without removal of thetransmission.


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7


Set-up

Adjust Clutch Linkage

0.00"

Hydraulic Linkages:Skip to Step 2.

Mechanical Linkages Only:Adjust the clutch linkage until theyoke fingerscontact the releasebearing(zero free-play incab).

Pressthe pedal to thefloorup to 5 times, this:

Movesrelease bearingslightly closerto thetransmission

Gainsfree-play incab

With the pedal up, measure thedistance betweenthe release bearing

and the clutch brake. The correctdistance should be 0.490"-0.560"(12.70-14.22 mm):

If the distance ismore the 0.560"(14.22 mm), returntoStep 1 andreadjust the clutch linkage.

If the distance islessthe 0.490"(12.70 mm), see Solo AdvantageHeavy-Duty 15.5" ClutchTroubleshooting. Go to

0.490"-0.560"(12.70-14.22 mm)

ReleaseBearing

ClutchBrake

YokeFinger

5X

1

2

3

page 10.
http://cmzz0048.pdf/http://cmzz0048.pdf/http://cmzz0048.pdf/


14/68

8


Verify Clutch Brake Squeeze

Verify Free-Play

Less than1"(25.4 mm)

Slowly let up onthe pedal andmeasure the pedal positionat themoment the gauge canbe removed: If pedal ismore than1" (25.4 mm)

from the floor, readjust the trucklinkage to move the yoke fingersfurtherfrom the release bearing.Returnto Step 4.

5

Have anassistant insert 0.010"(0.25 mm) feelergauge betweenthe release bearing and theclutch brake.

Pressthe pedal downto the floorto reclamp the gauge:

If the gauge doesnot clamp,readjust the truck linkage andmove yoke fingerscloserto

the bearing.

Use a gauge long enough to keephandsaway from moving parts.

4

WARNING

ReleaseBearing

YokeFinger

ClutchBrake

DO NOT RESET THE CLUTCH. Do not changefree-play by readjusting the clutch linkage.

Verify there isfree-play inthe cab. If not, the

truck linkage isnot providing enough stroke,consult OEM manual forfree-play dimension.ForSolo clutches, proceed to Step 8. ForSoloAdvantage clutches, proceed to Step 9.

6

IMPORTANT


15/68

9


Lubricate

InputShaft

Zerk

Input Shaft

Note: All clutchesuse a Lithiumcomplex grease with a minimumof 325F (163C) operating rangemeeting NLGI grade 2 or3 specs.

Foradditional lubricationinformation, see TCMT0021.

Apply grease to input shaftand yoke fingers.

28

Failure to properly lubricate thebearing/bushing will result inbearing and sleeve failures.

CAUTION

IMPORTANT

7 Apply ample grease that isvisiblyexiting the opening and contactsthe transmissionshaft. Thiswilllube the clutch brake and bushingwhenthe pedal ispressed.

Apply grease to the crossshaft bushingsand linkagepivot points.

9

Do not add lube (neverseize orgrease) to the input shaft splines.The disc must be free to move.


16/68

10


Troubleshooting for Solo AdvantageHeavy-Duty 15.5" Clutches

Symptom-Driven Diagnostics

No Clutch Brake:Too MuchClutch Brake:

Too MuchFree Pedal:

Pedal travelstoo little beforeengaging the clutch.

Pedal travelstoo farbefore engagingthe clutch. Clutch doesnot disengage.

Not enoughbrake squeeze

Notenoughtravel

Too muchbrake squeeze

Too

muchtravel

Not EnoughFree Pedal:

If clutch isout of vehicle, go to Out-of-Vehicle Resetting Procedure on

Based onyoursymptom, the chart willdirect youto the correct solution.

Go to page 11. Go to page 12.

Go to page 11. Go to page 12.

page 16.


17/68

11


Too Much Free Pedal or Too Much Clutch Brake

Measure distance

betweenrelease bearingand clutch brake.

1

Use chart to findsolution.

2

Measurement Status Solution

If distance iscorrect

0.490"-0.560"(12.45 - 14.22 mm)

If distance is

Less than0.490"(12.45 mm)

Clutch isset up correctly

Problem existswith truck linkage. Repairaccording to OEM specifications.

Hydraulic Linkage:

Clutch isnotset up correctly

ReleaseBearing

ClutchBrake

If clutch wasfactory installed and wasneverremoved orif clutch wasremoved from engineand reinstalled,

If new/remanclutch wasinstalled and it neveroperated properly, check weartab position.

If tab at GOOD position: Disc isinstalled incorrectly

Damperistoo large forthe flywheel opening

If tab not at GOOD position, the bearing mayhave beenpulled during installation, causinganoveradjust.

Note:Before measuring the distancebetweenthe release bearing andclutch brake depressclutch pedal toremove free pedal inthe cab.

Too muchbrake squeeze

Too muchtravel

go to page 13.

Go to page 3, Step 4 and 5.

Go to page 16.

Go to page 3, Step 1.

Go to page 49.


18/68


19/68


20/68

14


In-Vehicle Resetting Procedure Using the Solo Advantage Clutch Reset Tool

1 Determine if the release bearing travel iscorrect. Measure the distance betweentheclutch brake and the release bearing withthe clutch pedal up. If the measurement isbetween0.490" and 0.590", the Solo hasset itself correctly.

Note:Yoke gap only appliesto mechanical

linkage. Most hydraulic linkagesoperatewithout yoke gap.

Tool Part Code:RR1005CLK-Line 1-800-824-5546

2 If the release bearing travel islessthan0.490"the Solo must be reset. A commoncause of thisisthe transmissionwaspulled inwith the releasearm during clutch installation.

3 Rotate the engine so that the cam tab can

bereached th

rough the t

rans

miss

ioninspectionopening.

4 Push the clutch pedal to the floor. While the clutch pedalispushed to the floorhave someone push the cam tab tothe new positionusing fingerpressure orthe Solo tool.

Once the cam tab ispushed to the new positionyoucanrelease the clutch pedal.

Note:If the cam tab doesnot move, the

re i

snot e

noughrelease bearing travel to allow the camsto separate. In

thiscase, loosenthe transmissionand install 1/2"spacersbetweenthe flywheel housing and bell housing.

With the spacersinplace push the clutch pedal to thefloorwhile someone pushesthe cam tab to the newposition. Once the tab isinthe new positionrelease theclutch pedal and remove the spacers. Torque thetransmissionmounting bolts.

Release

Bearing

ClutchBrake

Measure the releasebearing travel

REPLACE


21/68

15


Verify Clutch Brake Squeeze

5 Install (4) shipping boltsand progressively tightenby hand until they bottom out. Rotate the engine toaccessall 4 bolts:

15 1/2" Solo use 7/16 x 14 UNC x 1 3/4"

Stamped 14" Solo use 3/8 x 16 UNC x 1 1/4"

Note:Thiswill reset the pressure plate separatorpinsand allow the clutch to release afterinstallation.

6 Remove the (4) shipping bolts. The release bearing andsleeve will move forward towardsthe engine whentheboltsare removed. The Solo isnow inthe new position.

8 Measure the distance betweenthe clutch brake and the releasebearing. It should be between0.490" and 0.590".

10 Adjust the clutch linkage toachieve 1/8" clearance betweenthe release yoke and therelease bearing. Verify properclutch brake squeeze.

9 If the release bearing travel isstillgreaterthan0.590" betweentheclutch brake and the releasebearing, repeat Steps 7 and8.

7 With the free pedal removed push the clutch pedal downat least 5 times. Make sure the clutch release bearingcontactsthe clutch brake.

While youengage and release the clutch the cab free pedalwill increase. Thisindicatesthe Solo isadjusting to theenvironment.

Shipping Bolts

Shipping Bolt

Tamper-Proof

Bolt

Slowly let up onthe pedal andmeasure the pedal positionat themoment the gauge canbe removed: If pedal ismore than1" (25.4 mm)

from the floor, readjust the trucklinkage to move the yoke fingersfurtherfrom the release bearing.Repeat Step 1.

Less than1"( 25.4 mm)

Have anassistant insert 0.010" (0.25 mm)feelergauge betweenthe releasebearing and the clutch brake.

Pressthe pedal downto the floortoclamp the gauge:

If the gauge doesnot clamp, readjustthe truck linkage and move the yoke

fingercloserto the bearing.

1

2

Use a gauge long enough to keephandsaway from moving parts.

WARNING

ReleaseBearing

YokeFinger

Clutch

Brake


22/68

16


Out-of-Vehicle Reset Procedure for Heavy-Duty ECA or Solo Advantage Clutches

Slide the wearindicatortab tothe GOODpositionand holdit inplace with a magnet

4

Install 4 shipping bolts(7/16" x 14 x1-3/4" UNC, hex head). Progressivelytighten(no airwrenches) the 4shipping bolts(crisscrosspattern)until the face of the pressure plate is1.75"-1.78" (44.4-45.2 mm) belowthe mounting surface.

5

Remove the 4 shippingboltsif they have beeninstalled.

1 Centerthe ram andpressdownward ontheretaineruntil it comesto

a stop. Lock the ram inposition.

3

Reinstall the clutch usingthe original installationinstructions.

6

Support the clutch inanarborpresswith the bearing facing down.

Shipping Bolts

Note: Make sure there isatleast 1" of space to allowthe bearing to movedownand to provideaccessto theshipping bolts.

Note: Thisimportant step will reset thepressure plate separatorpinsand allowthe clutch to release afterreinstallation.

2

1.75"-1.78"(44.4-45.2 mm)


23/68

17


Install Easy Pedal Advantage and ValueClutch


Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove andreplace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheelsurfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch.





Rotate flywheel onerevolution.Maximum runout is0.008" (0.20 mm).


2


3


1


2 3





2


3


3



1


24/68

18



Install 15.5" Clutch to Flywheel (Easy Pedal Shown)

Verify bearing positionis3/8"5/8"(9.515.9 mm) from cover.

9

Remove the aligning tool. Be sureshipping blocksare removed.

10

Use a six ounce hammerand a 1/4" flatnose punch to lightly tap the fourseparatorplate pinstoward the flywheel(New EP Only). Remanand Value clutchesdo not have pins. Only part of the pinshould be visible.

11 T O

TU RN

DE PR

ES S

B O L T

Pin

Use the EatonClutch SelectorGuide (CLSL1511)to make sure youhave the right clutch.

Anassembled clutch weighsabout 150 lbs(68 kg).Avoid the risk of injury. Use properequipmentwhenlifting a clutch.

Progressively tightenmounting boltsina crisscrosspatternstarting with the

lowerleft bolt (1, 2, 3, 4, 5, 6, 7, 8).Torque to 40-50 lb-ft (54-68 Nm).Failure to do thiscould result inimproperpiloting of the clutchand cause clutch damage.

8

Install lock washersand mountingbolts(7/16" x 14 UNC x 2-1/4"grade 5) fingertight. Replacestudswith lock washersand bolts.

7

Install second disc onto aligningtool. Follow the orientationinstructionsonthe disc.

5

Install intermediate plate into slotsonthe clutch cover. Flywheel Sidemust face the flywheel.

4

Install disc onto aligning tool.Follow the orientationinstructionsonthe disc.

3

Insert aligning toolthrough bearing.

2

Note:Wheninstalling clutch to flywheel, positionthe adjusterat the bottom of flywheel to easefuture clutch servicing.

Note:Easy Pedal ormanual adjust clutchassembliesnot recommended foruse withhydraulic release systems.

Install two 7/16" x 14UNC x 5" studsinto uppermounting holes. Install

assembled clutch.

6

1

3

4

5

6

7

8

TOTU

R N

DEPRE

SS

B O

L T

2

IMPORTANT WARNING

Measure the flywheel bore.Use the EatonClutchSelectorGuide to verify thatthe damperwill fit into theflywheel bore.

7.0" (8-spring) 8.5" (10-spring) 10.0" (7-spring and Mack 9-spring)Note: Mack 9-spring forMack and Volvo

engines2007 and neweronly.

1


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19


Install 14" Clutch to Flywheel

Install three equallyspaced anti-rattlesprings.

Note:Checkorientationonanti-rattle springsbefore installing.

3

Super-duty clutch only:

Ensure the correct flywheeldepth is2-15/16".

1

Put front disc into flywheel.Flywheel side must be towardengine. Use new slotsto putintermediate plate onpins.

2

Turnintermediate plate left. Use0.006" feelergauge to check leftpinclearance onall 6 drive pins.

Note:Remove two set screws.Straightenpinsto increaseclearance and reinstall setscrews. Do not file slots.

4

Slide coveroveraligning tool.

10

Install disc intoflywheel. Followthe orientationinstructionsonthe disc.

6

Installintermediateplate ontodrive pins.

7

Install seconddisc ontoflywheel. Followthe orientation

instructionsonthe disc.

8

Progressively tightenmounting boltsina crisscrosspatternstarting with thelowerleft bolt (1, 2, 3, 4, 5, 6, 7, 8).Torque to 25-35 lb-ft (34-47 Nm).Failure to do thiscould result inimproperpiloting of the clutch andcause clutch damage.

12 Remove the aligningtool. Be sure shippingblocksare removed.

13

Install two 3/8" x 2-1/2"studsinto uppermounting holes.

5

Insert aligning

tool throughdiscs.

9

1

3

4

5

6

7

8 2

TOTURN

DEPR

ESS

B O

LT

Install lock washersand mountingbolts(3/8" x 1-1/4" grade 5) fingertight. Replace studswith lockwashersand bolts.

11


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20



Check Transmission For WearReplace any worn components.

IMPORTANT

Do not add lube (neverseize orgrease) to the input shaft splines.The discsmust be free to move.

Input Shaft SplinesAny wearonthe splineswillprevent the drivendiscsfromsliding freely, causing poorclutch release (clutch drag).Slide discsfull length of shaft to

check fortwi

sted

shaft

spli

nes.

Clutch BrakeReplace.

Cross Shaft andBushingsExcessive wearat these pointscancauseside loading onthe sleeve bushing,bushing failuresand yoke bridge contactwith the clutch whenthe pedal isdown.

Measure Input ShaftLength should be 8.657" (219.89 mm) nominal, and notgreaterthan8.71" (221.23 mm). Ref. 1990 SAEhandbook 4:36.106. Replace transmissionbearingretainercap if length isgreaterthan8.71" (219.89 mm).

TransmissionBearingRetainerCapA worn/rough bearingretainercap may causethe clutch brake to wearprematurely.

Release YokeWornfingerscancausebushing wearand yokeinterference whenthepedal isdown.

Input Shaft

Wear(roughness) canreduce sleeve bushing lifeand cause it to come out.

CAUTION

Do not excessively force the transmissioninto the clutch assembly orenginehousing. Thiswill cause damage to thesplinesof the reardisc hub that isnotwarrantable. If the discsdo not slide freely

onthe input shaft, investigate the cause ofthe problem and make any necessarychanges. If the discsdo not slide freely, theclutch will not release and the transmissionwill grind going into gear.

Do not let the transmissiondrop orhangunsupported inthe drivendiscs. Thiscanbend the discsand the clutch will notrelease causing damage that isnotwarrantable.


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21



Transmission installation and clutch set-up procedures are the same for the 14" and 15.5" clutch.

1 Put transmissioningear.

Besur

en

ew clu

tch br

akehasbeeninstalled.

3 Positiontransmissionso it issquare to andaligned with engine.

4 Mesh splinesby moving transmissionforward and rotating the output shaft.

Do not use excessive force. Do not letthe transmissionhang unsupportedinthe discs.

5 Install mounting boltsandtorque to OEM specs.

Note:If youhave a hydrauliclinkage,

2 Make sure that the yoke

fin

gers

r

emain

in

theu

ppositionuntil they are overthe release bearing housing.

CAUTION

IMPORTANT

Do not add lube to the input shaftsplines(Neverseize orgrease). Thediscsmust be free to slide.

Do not force transmissionagainst clutchwith yoke fingersinthe up position. Thiswill break the cast webbing of the clutchcausing damage that isnot warrantable.

Do not use excessive force. If it doesnotenterfreely, investigate the cause ofproblem and make any necessary changes.

Do not let the transmissiondrop orhangunsupported inthe drivendiscs. Thiscancause the discsto become distortedand the clutch to not release.

WARNING

go to page 49.


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22


Set-Up

Adjust Bearing Position

Measure the distance betweentherelease bearing and the clutch brake:

If thedistance iscorrect,0.500" -.0560" (12.70 - 14.22 mm),thenVerify Clutch Brake Squeeze,go to Step 4.

If the distance isnot between500" -.560" (12.70 - 14.22 mm),thenChange Bearing Position,go to Step 2.

1

0.500" -0.560"(12.70 - 14.22 mm)

ReleaseBearing

Hold

ClutchBrake

Have anassistanthold downclutchpedal so internaladjustment canbe made.

2

3 Adjust bearing position:

Note: Before measuring the distance betweenthe release bearing and

clutch brake depressclutch pedal to remove free pedal inthe cab.

TOTURN

DEP

RES

S

BOL

T

Adjusting NutPart Number125489

While pedal isheld down, remove lockstrap andmove adjusting lug:

If measurement wasmore than0.560" (14.22mm), move adjusting lug to the left (shown).

If measurement waslessthan0.500" (12.77 mm),move adjusting lug to the right.

Lockstrap

AdjustingLug

Easy-Pedal & Easy Pedal Advantage Only: Value Clutch Only:

While pedal isheld down, push adjusting nut and turn:

If measurement wasmore than0.560" (14.22 mm),turnadjusting nut clockwise.

If measurement waslessthan0.500" (12.77 mm),turnadjusting nut counterclockwise.


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24


Verify Free-Play

1/8"(3.2 mm)

ReleaseBearing

YokeFinger

6 Measure the distance betweenyoke tipsand bearing wearpadssimultaneously. Thisdistance

should be 1/8" (3.2 mm). Ifdistance isnot 1/8" (3.2 mm),go to Step 7.

Do not change free-play by changing the bearingposition. Correct bearing positionis0.500"-0.560"(12.70 - 14.22 mm)

The truck linkage should allow fora minimum of0.685" of yoke fingermovement; 0.125" forfree-play, 0.500" forthe bearing and 0.060" forclutch brake squeeze. If it isnecessary to increasethe free-play, adjust upperpedal stop to raise or

lowerthe pedal i

nthe cab. If thi

sisnot po

ssible,check the OEM partsmanual to verify the correct

clutch arm wasinstalled at the factory.

7

Do not change bearing position.

Note:1/8" (3.2 mm) distancewill create free-play incab.Free-play incab may bedifferent ondifferent truckmakes, modelsand years.

IMPORTANT

IMPORTANT

1/8"(3.2 mm)


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25


Lubricate

Zerk

Note: All clutchesuse a Lithium

complex grea

se with aminimum of 325F (163C)

operating range meeting NLGIgrade 2 or3 specs.

Note: Apply ample grease thatisvisibly exiting the openingand contactsthe transmissionshaft. Thiswill lube the clutchbrake and bushing whenthepedal ispressed.

Foradditional lubricationinformation, see TCMT0021.

YokeFinger

Failure to properly lubricate thebearing/bushing will result inbearing and sleeve failures.

Input Shaft

Apply grease to inputshaft and yoke fingers.

8

Apply grease to the crossshaft bushingsand linkagepivot points.

29

CAUTION

IMPORTANT

Do not add lube (neverseize orgrease) to the input shaft splines.The disc must be free to move.


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26

UltraShift DM Clutch

UltraShift DM Heavy Duty Clutch

Remove Clutch

Priorto removing the transmission, rotate the engineuntil one of the jack screw locationscanbe viewedthrough the clutch housing inspectionopening.

1

Using a piece of 5/16" x 18 UNC x 3"threaded rod (jack screw), installtwo nutsonone end and lock themtogether. Thiswill allow youto turn

the jack screw inand out of thecoverassembly.

2

Anassembled clutch weighsabout 182lbs(82 kg). Avoid the risk of injury. Useproperequipment whenlifting a clutch.

Do not overtightenthe jack screw.Tightening more than9 lb-ft cancause permanent clutch damage.

CAUTION

Remove thejack screw.

6

Remove the transmission,supporting itsweight toprevent damage to theclutch discs.

4

Install the jack screw into one of thefourholeslocated adjacent to theclutch mounting bolts. Thisforcesthe pressure plate forward clampingthe discsand holding them inplace.

3

Insert alignment shaftand clutch jack.

5 Remove the oldpilot bearing.

8

CAUTION

Unbolt the clutch from theflywheel and slide the clutchaway from the flywheel.

7

Anassembled clutch weighs

about 182 lbs(82 kg). Avoidthe risk of injury. Use properequipment whenlifting a clutch.

Whenremoving the clutch, theflywheel side disc canfall off ofthe alignment shaft, permanentlydamaging the drivendisc.

WARNING

WARNING


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29



Check Transmission for WearReplace any worn components.


Input Shaft SplinesAny wearonthe splineswill preventthe drivendiscsfrom sliding freely,causing poorclutch release (clutchdrag). Slide discsfull length of shaftto check fortwisted shaft splines.

1

IMPORTANT

Do not add lube (Neverseize orgrease) to the input shaft splines.The disc must be free to slide.

Do not use excessive force. If itdoesnot enterfreely, investigatethe cause of problem and makeany necessary changes.

Do not let the transmissiondrop orhang unsupported inthe drivendiscs.Thiscancause the discsto becomedistorted and the clutch to not release.

CAUTIONWARNING

5 Reconnect UltraShiftwiring harness.

1 Positiontransmissionso it issquareto and aligned with engine.

2 Mesh splinesby movingtransmissionforward and rotatingthe input shaft. Do not use excessiveforce. Do not let the transmissionhang unsupported inthe discs.

4 Remove the jack screw.

3 Install mounting boltsandtorque to OEM specs.


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Heavy-Duty UltraShift Clutch Recalibration

1. Turn key on.

2. Verify a solid N is on the gear display.

3. Start engine.

4. Increase engine RPM above 1500. This will unlockthe clutch. Failure to do this will set a clutch disen-gagement code and the code and transmission willnot go into gear.

Note: Programmable VSS Tamper Resistance options or other

artificial engine speed limits which prevent reaching therequired 1500 rpm may prevent proper disengagementof the clutch locking device after initial installation.These options may need to be disabled until after theclutch-locking device is disengaged.

Note: If ServiceRanger is available, proceed to Step 12.

5. Start with the system powered down, the vehicle sta-tionary, and the engine not running.

6. Key on and allow the system to completely power upbut do not start the engine.

7. Select LOW mode on the shift controller (UltraShift

system will begin to emit an audible tone).

8. Select an upshift once (UltraShift gear display willdisplay a 0 with down arrows and discontinue thetone indicating Special Functions mode is acti-vated.

9. Once in Special Functions mode, select one addi-tional upshift (UltraShift gear display will display a

1 with up arrows indicating UltraShift Touch PointResent is selected.)

10. After the 1 is displayed, depress the throttle pedalto the floor and hold for 3-5 seconds (the gear dis-play will change back to a 0 with down arrows indi-

cating the routine has been successfully completed.

11. Key off or select any mode and the UltraShift systemreturns to normal operation.

12. Save clutch data / recalibrate clutch with Ser-viceRanger.

1


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Gen 2

Using ServiceRanger, select the Advanced ProductFunctions button located on the main menu.

Select Eaton AutoShift Gen-2 from the productselection screen.

Note: This screen will only appear if the vehicle is equippedwith more than one supported Roadranger product.

Select Clutch Data from the Advanced ProductFunctions screen.

Save the clutch data by selecting the Save AbuseInfo to a File button.

Note: Use the truck VIN as the file name. The data file will besaved to the ServiceRanger folder in the Clutch Datasubfolder (e.g. C:\Serviceranger\Clutch Data).

Reset clutch abuse info by selecting the ResetClutch Abuse Info button.

Recalibrate the new clutch by selecting the CalibrateClutch button.

Note: Failure to calibrate a newly installed clutch may result insome initial harsh vehicle launches, as the system isrequired to manually recalibrate.

Gen 3

Using ServiceRanger, select Advanced ProductFunction button.

Select UltraShift transmission model (Gen 3) frommenu tree in the upper left.

Select the VPA/SnapShot Utility and launch the func-tion.

Read the APF description and select Next.

Enter the vehicle info and select Next.

Select VPA from the dropdown Data Source field.

Enter an output file name and location using BrowseButton or use default filename and location shown.

Note: If the default filename and location is used, the VPA

data file will be saved to the ServiceRangerData folderin the VPA subfolder on the C:\drive.

Select the Start Transfer button to download datafrom transmission controller and then select Next.

The output file can now be viewed, select Finish.

Select Clear Clutch Data button to clear data fromtransmission controller.

If successful proceed to next step, if unsuccessfulexit function and re-enter. Contact Roadranger CallCenter 1-800-826-4357 for help.

Select the Calibrate Clutch button to calibrate newclutch and the select Finish when complete.


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ECA Clutch

Remove Clutch

Note the position of the wear indicating tab on the clutch. Ifthe tab is near the REPLACE position, the clutch should bereplaced.

1. Use Eaton Service Ranger Diagnostic Software inorder to command the ECA to open the clutch.

(If clutch is to be reinstalled andtransmission is still in vehicle)

Opening the ECA Clutch

CAUTION

Turnignitionswitch to on.

A FFO

NO

TRATS

B Plug 9-pinconnectorinto dash port.

3 Click onServiceRangericonto launch program.

C

CAUTION

Ensure that handsare not inside the clutchhousing while opening orclosing the clutch.


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33

ECA Clutch

Openand expand theAdvanced ProductFunctionstree.

D F Click onECA ClutchService.

E Click ontransmission.

Note: Advanced ProductFunctionsappear.

CAUTION

Ensure that handsare notinside the coltish housing whileopening orclosing the clutch.

Choose ClutchPositiontab.

G

Click OpenClutch button.

Note: ServiceRangerwillrequire engine running inorderto openclutch.

H

I Confirm Positive results.


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34

ECA Clutch

2. Slide the wear indicating tab to the left until it is atthe NEW position.

Note: If the cam does not move, loosen transmission andinstall 1/2" spacers between clutch housing to increasestroke.

3. Without cranking the engine, close the clutch by

switching the ignition to ON, and the wear indicatingtab will stay in the NEW position.

Ensure that hands are not inside the clutch housing whenopening or closing the clutch.

4. Remove the transmission, supporting its weight toprevent damage to the bearing and discs.

5. Locate 4 shipping bolts (7/16" x 14 x 1 3/4" UNC, hexhead). Install them in the 4 cover holes hand tightthen turn one full turn.

This step will hold the pressure plate separator pins in properposition so the clutch can be reused and will release afterreinstalling.

6. Support the clutch during the removal of the 8mounting bolts.

7. Remove the clutch from the flywheel.

REPLACE

CAUTION

IMPORTANT

Shipping Bolts(4) 7/16" x 14 x 1-3/4" UNC


41/68

35

ECA Clutch

15.5" Heavy-Duty ECA Clutch Installation


Engine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove andreplace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheelsurfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch.





Rotate flywheelone revolution.Maximum runout is0.008" (0.20 mm).


2


3


1


2 3





2


3


3



1


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36

ECA Clutch


Progressively tightenmounting boltsina crisscrosspatternstarting with thelowerleft bolt. Torque to 4050 lb-ft(5468 Nm). Failure to do thiscouldresult inimproperpiloting of the clutchand cause clutch damage.

5

Slide the clutch assembly overthe guidestudsand install six lock washersandmounting bolts(7/16" x 14 UNC x 2 1/4"grade 5) fingertight. Replace studswithremaining two lock washersand bolts.

4

Insert aligning tool throughbearing.

Note:The ECA Clutchalignment tool isa 14-toothshaft and is1-3/4" longerthanthe standard shaft.

1 2 Install second disc ontoaligning tool. Follow theorientationinstructionsonthe disc.

Install two 7/6" x 14 UNC x 5" studsinto uppermounting holes. Installassembled clutch.

3

1

3

4

5

6

7

8

2

8 Positionthe releasebearing so the orientationof the lube fitting isinthe4 o'clock position.

Remove aligning tool.7

Remove fouryellow shippingboltsinaneven1/4 turncrisscrosspattern.

6

Generic graphic

Note:The clutch release yoke fingersmust bepositioned so they clearthe release bearing housingwhenremoving and installing the transmission.

Preferredmethod:Move the release yoke to theservice positionvia ServiceRanger'sAdvancedProduct Functions.

Secondary method:Remove the ECA priortoremoving the transmissionand thenmanipulatethe fingersby hand.

Do not unbolt the intermediate plate from thecoverassembly.

Do not use vehiclestransmissionto installthe ECA clutch, asit canresult indamage tothe clutch orECA.

Anassembled clutch weighsabout 150 lbs(68 kg). Avoid the risk of injury. Use proper

equipment whenlifting a clutch.

CAUTION

WARNING

9 Following transmissioninstallation, performclutch adjustment. See the "ECA ClutchAdjustment" Sectiononpage 40.

Note: Alwaysperform a clutch adjustmentaftera clutch replacement.


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37

ECA Clutch



Input ShaftWear(roughness) canreducesleeve bushing life and causeit to become dislodged.

Low Capacity Inertia Brake (LCIB)Eatonrequiresthat youreplace theLCIB whenreplacing the clutch. SeeAppendix A forLCIB removal andinstallationinstructions.

Cross Shaft AndBushingsExcessive wearat these points

cancause side loading onthesleeve bushing, bushingfailuresand yoke bridgecontact with the clutch intherelease/openposition.

Input Shaft SplinesAny wearonthe splineswillprevent the drivendiscsfromsliding freely, causing poorclutchrelease (clutch drag). Slide discsfull length of shaft to check fortwisted shaft splines.

Release YokeWornrollerscancausebushing wearand yokeinterference whentheElectronic Clutch Actuatorisat the released position.

Note:Check transmissionforwearand replace any worncomponents.

1 Put transmissioninneutral. Be sure newLCIB hasbeeninstalled.

3 Positiontransmissionsoit issquare to and alignedwith engine.

4 Mesh splinesby moving transmissionforwardand rotating the input shaft. Do not useexcessive force. Do not let the transmissionhang unsupported inthe discs.

6 Install mountingboltsand torqueto OEM specs.

2 Make sure that the yoke fingersare rolled and remaininthe uppositionuntil they are overtherelease bearing housing.

5 Before installing the mountingboltsthe lube tube will haveto be reconnected to theclutch housing.

Generic graphic

Note:If the ECA hasbeenremoved, ensure the yoke fingersremaininthe up position. Use the openingvacated by the ECA to rotate the yoke inthe up positionjust before the transmissionisgoing to be aligned.


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38

ECA Clutch

Install Electronic Clutch Actuator (ECA)

2 Install the ECA into the clutch housing boreand alignit with the lowercross-shaft.

Note:The ECA will have to be rotated to alignwith the slot inthe clutch housing.

4 Install the 4 cap screwsforthe ECA bracket and tightento 35 - 45 lb-ft (47 - 61 Nm).

5 Apply Eatonlubricant (P/N5564527) to the 8 and 3-wayconnectorterminalsandreconnect the connectorstothe ECA.

6 Reconnect the negative12-volt battery cable.

Note:Ensure yourotate the release yokeclose to the cast dowel inthe clutch housingpriorto mating with the cross-shaft. This

allowsthe release yoke to clearthe releasebearing during installation.

3 Install the 4 cap screwsfrom theECA mounting flange and tightento 35 - 45 lb-ft (47 - 61 Nm).

Note:The 4 cap screwsforthe ECA arelongerthanthe ECA bracket cap screws.

1 Apply a 1" band of anti-seizeto the barrel of the ECU.

1"


45/68

39

ECA Clutch

Lubricate

1. Open the inspection cover and verify the cross-shaftand release bearing lube tubes are properlyattached and functional.

Note: Failed lube lines will prevent grease from reaching therelease bearing causing premature clutch release bear-ing failure.

2. Apply grease through the release bearing lube tubeand continue to apply lube to cause enough greaseto purge out of the release bearing housing andonto the transmission input shaft.

Note: Do not be concerned if excess grease gets onto theLCIB friction surface, it will not affect the brakes stop-ping ability.

3. Apply grease to the cross-shaft bushing lube tubeso that a visual purge can be observed at the cross-shaft bushing weep hole.

4. Reset the grease interval count if the optional auto-mated lube schedule has been activated.

Note: See the Grease Interval Count Reset section.

IMPORTANT

Do not add lube (neverseize orgrease)to the input shaft splines. The discmust be free to slide.

CAUTION

Failure to properly lubricate thebearing/bushing will result inbearingand sleeve failures.

Greaseshouldpurgeonto InputShaft.

Cross-shaftGrease

Fitting

ReleaseBearingGreaseFitting

InspectionCover

Cross-shaftBushingWeep Hole

Cross-shaftLube Tube

Release BearingLube Tube

Note: Zerk fittingsarelabeled RS(Release Bearing)and CS(CrossShaft) ontheclutch housing case.

Note: All clutchesuse a lithiumcomplex grease with a minimum of325F (163C) operating range

meeting NLGI grade 2 or3 specs.


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40

ECA Clutch

ECA Clutch Adjustment

This command signals the ECA to actuate the clutch in order to set the adjustment after an ECA Clutch has been reset orreplaced. Fault code 26 or 27 indicate that the clutch may have come out of adjustment. Refer to Troubleshooting GuideTRTS0930 for more fault code detail. A clutch adjustment should always be performed after a clutch replacement.

Openand expand the AdvancedProduct Functionstree.

4 5 6 Click onECAClutch Service.

Click ontransmission.

Note:Advanced ProductFunctionsappear.


1 FFO

NO

TRATS

2 Plug 9-pinconnectorinto dash port.


3


47/68

41

ECA Clutch

Click onRequest Clutch Adjustment.

Note: ECA will actuate the clutch five

timesto perform adjustment.

Choose ClutchPositionTab.

7 8

9 Confirm Positive results.


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42

ECA Clutch

Grease Interval Count Reset

The Heavy-Duty UltraShift PLUS has an optional prognostic feature that notifies the operator when the Clutch Release Bearingneeds greasing. This feature can be enabled or disabled via ServiceRanger.

At the appropriate grease interval and shortly after each engine start, GI will momentarily appear in the gear display, along withan audible tone. This will continue to occur at each engine start until clutch service has been completed. Note:GI stands forgrease interval and may be misread as G1 on gear display.

The operator can choose to follow this Automated Lube Schedule or the published lube guidelines in the Lubrication ManualTCMT0021. When enabled, it is highly important to reset the Grease Interval Count every time the release bearing is greased.

The Grease Interval Count can be reset via ServiceRanger or Operator Triggered Special Function.

ServiceRanger Procedure


A FFO

NO

TRATS



C

CAUTION



49/68

43

ECA Clutch

Choose GreaseInterval Reset tab.

7 Click onClearGreaseInterval Counter.

8

9 Confirm Positiveresults.

10 Turnignitionswitchto off to save reset.


4 6 Click onECAClutch Service.

5 Click ontransmission.

Note:Advanced ProductFunctionsappear.


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45

ECA Clutch

ECA Clutch In-Vehicle Resetting Procedure

1. Measure distance between release bearing and LowCapacity Inertia Brake (LCIB):

It is necessary to compress the LCIB to a solid

condition prior to measuring the distancebetween the LCIB and the release bearing. Ascrew driver can be used to compress the LCIB.

With the LCIB compressed, proceed in measur-ing the distance between the release bearingand LCIB. If the measurement is not between0.490" and 0.560" reset clutch. Go to Step 2.

2. Eaton Service Ranger Diagnostic Software is neededto command the ECA to open the clutch.

Note: Keep the ECA Clutch Service Utility open. It will beused again during this process.

LCIB

Correct Distance =0.490" - 0.560"

ReleaseBeaing

Opening the ECA Clutch


A FFO

NO

TRATS


3 Click onServiceRangericon

to laun

ch prog

ram.

C

CAUTION



52/68

46

ECA Clutch

Choose Clutch

Positiontab.

G

Click OpenClutch button.

Note: ServiceRangerwillrequire engine running inorderto openclutch.

H

I Confirm Positive results.

Note:Keep the ECA ClutchService utility open. It will beused againduring thisprocess.


D F Click onECA ClutchService.

E Click ontransmission.

Note: Advanced ProductFunctionsappear.

CAUTION

Ensure that handsare notinside the clutch housing whileopening orclosing the clutch.


53/68

47

ECA Clutch

Verify reset.Go to Step 1.

10

PositionReset Tool: Through the accesspanel

Underthe release bearing

With threaded bolt incam slot

4

Turnignitionswitch to off.3

NEW

sseccA

Shipping Bolts

lenaP

Without cranking the engine, close theclutch by switching the ignitionto ON.

Ensure that handsare not insidethe clutch housing whenopeningorclosing the clutch.

6

CAUTION

Use tool to move cam toGood position.

Note: If the cam doesnot move,

loosentrans

miss

ionand i

nstall 1/2"

spacersbetweenclutch housing andengine housing to increase stroke.

With spacersinplace, follow Steps 2through 6inthisprocedure.

Remove spacersand torque transmissionmounting bolts.

Continue processstarting at Step 7.

5

NEW

erofeB

gnippihStloBpaG

oNpaG

eveelSniP

retfA

Install and tighten4 shippingbolts(7/16" x 14 x 1-3/4 UNC)to remove gap betweensleeveand pin.

7

Inthe ECA Clutch Serviceutility, select the RequestClutch Adjustmentcommand, and followServiceRangerinstructions.

Note:The Request ClutchAdjustment command willautomatically initiate the ECAto openand close the clutch,causing a clutch adjustmentto take place.

9

Remove the 4 shippingboltsina crisscrosspatterna 1/4 turnat a time.

8


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49

Hydraulic Linkage

Hydraulic Linkage

Verify Linkage System Stroke

Measure the release bearing position with the pedal up andpedal down to verify bearing travel.

The hydraulic linkage should allow for a minimum of 0.600" ofyoke finger movement: 0.500"-0.560" for clutch release plusadditional movement for clutch brake squeeze.

If the system does not provide enough movement of therelease bearing, the clutch will not adjust and the bearing willmove away from the transmission and lose clutch brakesqueeze.

If the system is operational, clutch replacement may be nec-essary. If replacing the clutch, you must adhere to OEM war-ranty guidelines prior to claim disposition.

Master Cylinder Installation

Master Cylinder

Master cylinder may be mounted at any angle ranging fromvertical to horizontal, depending on application.

Remote Reservoir

Constant rise in hose from master cylinder to reservoir.

1 - Master cylinder2 - Reservoir3 - Pushrod4 - Bolts (2), M8 x 1.25 mm (torque 20-25 Nm)5 - To booster or slave

3

5

1

4

2


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50

Hydraulic Linkage

Adjustment

Freeplay

Depending on the application, freeplay can be achieved by

adjusting upper pedal stop or by adjusting master cylinderpushrod.

Clutch Brake Squeeze

For non-synchronized applications only.

Transmission Installation

Non-Synchronized

Slave Cylinder

1 - Freeplay 3-8 mm

1 - Clutch brake squeeze 13-50 mm

1

1

1 - Clutch servo2 - To master cylinder3 - Connect air supply 30 psi source; Bolts (4),

M16 x 1.5 mm (torque 20-25 Nm)

4 - Bolts (2), M8 x 1.25 mm (torque 20-25 Nm)5 - Pushrod

1 - Slave cylinder

2

5

3

4

1

1


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51

Hydraulic Linkage

Synchronized

Clutch Servo

Hose Assembly

1. Connect hose assembly to master cylinder and slaveor booster. Depending on hose type, this is either athreaded connect or snap-to-connect. Torque all

connectors to 20-25 Nm.

Note: Make sure there is a constant rise to the mastercylinder.

Snap-to-Connect

Threaded Connect

Fill Procedure

Recommended methods are vacuum fill or pressure fill. Referto OEM procedure.

Do not press or disengage clutch pedal when removing slave

cylinder or clutch servo.

1 - Pushrod2 - Slave cylinder3 - To master cylinder4 - Bolts (4), M8 x 1.25 mm (torque 20-25 Nm)

1 - Clutch servo

3

1

4

2

1

CAUTION


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Hydraulic Linkage

Solo Advantage Lube Hose Assembly With Hydraulic Linkage

Installation Process

1. Install brass fitting into grease port on left side ofrelease bearing housing using Weatherhead socket.Tighten hand tight and continue to turn until theopening of the fitting is facing toward the 6 oclockposition

2. Install lube hose into brass fitting and tighten untilhand tight, then turn an additional 2 turns.

3. Lubricate release bearing until grease purges fromrelease bearing housing. Use NLGI #2 or #3 Lithiumcomplex grease. Reference Eaton lubrication manualTCMT0021 for specific instructions.

4. Install hand hole cover A-8173 with grommet biasedtowards transmission in the clutch housing. Securethe hand hold cover with two 5/16 x 18 x 1/2 inchlong bolts.

5. Insert plug into hole in upper left side of the clutchhousing where the horizontal lube hose is utilized.

Note: If the lube hose assembly should need servicing it canbe replaced without removal of transmission.

Parts Required:1 - K-4050 Lube hose assembly kit

(includes brass fitting, lube hose, and plug)

2 - A-8173 Hand hold cover with grommet


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Hydraulic Linkage

1. Fitting is assembled to hose hand tight. Attach thebrass fitting to the release bearing housing handtight and turn fitting until opening of fitting is at the 9oclock position when facing the engine. Install thehose into fitting until hand tight and turn 1/6 turn.Refer to diagram.

2. Transmission installation; remove the nuts from thebrass fitting with the grease zerk. Install the trans-mission and insert the brass fitting through the holein the left side of the clutch housing. Reinstall thebrass nuts and tighten.

3. Lubricate release bearing until grease purges fromrelease bearing housing. Use NLGI #2 or #3 Lithiumcomplex grease. Reference Eaton lubrication manualTCMT0021 for specific instructions.

4. Install 4305231 hand hole cover to protect the clutchfrom contamination.


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General Information

General Clutch Information

Function of a Clutch

Any modern day clutch, whether designed for an automobileor heavy truck, performs several important tasks allowing forsafe and convenient operation of the vehicle.

In a vehicle powertrain, the clutch is the device that interruptsthe flow of power from the engine flywheel to the transmis-sion. To start a gasoline or diesel engine, the flywheel must beable to turn freely without propelling the vehicle. By disengag-ing the clutch, the drivetrain is effectively disconnected fromthe rotation of the flywheel allowing the engine to start.

Manual transmissions, whether synchronized (synchromesh)or non-synchronized (constant mesh), require an interruption

of engine torque to complete a gear change. To make a gearchange, the clutch pedal is depressed, breaking torque. Thisis followed by altering engine speed to more closely match thetransmission input shaft (clutch disc) speed. After the propergear is selected, the clutch pedal is then slowly released. Asthe clutch disc(s) are compressed, the relative slip speedbetween the flywheel and the transmission input shaft reacheszero and the clutch is completely engaged and capable of car-rying full engine torque. With non-synchronized gearboxes,double clutching (a momentary partial engagement of theclutch made while the transmission is in neutral) is often nec-essary to allow rotational speeds of gears to become thesame and complete the gear change.

With the advent of transmission automation, breaking torqueand altering flywheel speed is accomplished via electronicthrottle control and engine braking. The clutch pedal is usedonly when starting the engine, launching the vehicle from astop, and when the vehicle slows to a stop.

The last function of the clutch is mitigating torsional vibra-tions. With any in-line, six-cylinder engine there are three (3)distinct power pulses occurring during each revolution of theflywheel. With each firing of a cylinder, the flywheel speeds upthen slows down, very quickly, resulting in a torsional vibra-

tion. This vibration can damage drivetrain components inshort order if left uncontrolled. The coil springs in a drivendisc damper absorb much of the vibration. The resonant (gen-erally the least expensive drivetrain component) is consideredthe fuse of the system. Failure of a clutch damper section isusually an indication of a serious torsional vibration systemsproblem or shock loading due to driver abuse.

Clutches are assemblies made up of many different compo-nents utilizing many different types of materials. This section

describes the major components which make up a completeEaton Clutch installation.

The following are the major components used to make up aclutch installation:

Cover Assembly (contains pressure plate) Intermediate Plate (only in 2-plate clutches) Driven Disc(s) Clutch Brake

Neutral Idle Rattle

Neutral idle rattle is a system issue. It occurs when the engine

is idling with the transmission in neutral and the clutch pedalin the up position. As the engine idles, the firing pulses causethe flywheel to oscillate as it is rotating. This oscillation istransmitted through the input shaft and into the transmissiongearing. This oscillation causes the transmission gears toimpact one another resulting in a sometimes objectionablenoise. While this noise is an annoyance, it is in no way dam-aging to the transmission and other components.

In the past, free travel dampers have been used to overcomethis phenomenon. As systems have changed, in terms ofmass, inertia, and fuel injection pressures, free travel hasbecome a less effective means of control.

Free travel, simply stated, is the free left or right rotation ofthe driven disc hub before engaging the clutch damper. Thisfirst stage isolates some of the flywheel oscillation energy andprevents or reduces the idle rattle.

Pre-damper technology is now available in some medium-and heavy-duty clutch applications and performs the samefunction as the free travel. By adding a dampened first stage,it is more effective at limiting neutral idle rattle. Generally, thepre-damper springs are very small and softer in rate than themain damper springs.

In diagnosing neutral idle rattle complaints, first try to fullydepress the clutch pedal. This will disconnect the engine fromthe transmission. Secondly, try raising the engine idle speedwith the clutch pedal up. This may smooth out the engine fir-ing and may reduce, or eliminate, the noise.

If you have neutral idle rattle, determine what clutch isinstalled in the vehicle. It may already have a pre-damperclutch in it. If it is already equipped with a pre-damper clutch,then there is no benefit to changing the clutch.


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General Information

Self-Adjusting Clutches

The Eaton Solo is the industrys first adjustment-free clutch.With every push of the pedal, Solos innovative wear-adjustingtechnology senses for wear and makes any adjustments nec-essary.

Why There is No Need to Adjust Eaton Self-Adjusting Clutches

If the Self-Adjusting Clutch is properly installed and the link-age is set-up properly, the Self-Adjusting Clutch should neverneed internal or external adjusting.

The Self-Adjusting Clutch automatically keeps the properrelease bearing position and clutch free pedal position withtwo opposing cams. As the Self-Adjusting Clutch wears, the

cams separate from each other keeping the proper releasebearing position. This in turn maintains the proper clutch freepedal position.

How it Works

Eaton Self-Adjusting Clutches wear-adjusting technologycomes from two sliding cams. With every push of the pedal,the clutch senses for wear and makes any adjustments neces-sary. The cams rotate to maintain the proper adjustmentthroughout the life of the clutch. On top of the upper cam, aclutch wear indicating tab mirrors the camsmovement to let

you know when its time to replace the clutch. The result ofSolos constant adjustment is greater longevity and a reduc-tion in maintenance and labor costs.

Clutch Disc Dampening Characteristics

A key function of a clutch is to mitigate naturally occurringvibrations of the engine flywheel from reaching the transmis-sion and the other components further down the drivetrain.This is accomplished by employing torsional spring dampersto the clutch pack. These springs take the form of coil springs,configured inside the clutch disc, that compress with the

application of torque. The torque path through the damperbegins at the friction interface at the facings, proceeds to thesteel carrier disc and moves into the disc reinforcing plateswhere the springs are located. The springs are compressed,transmitting force to the spring covers which are rigidlyattached to the hub. Torsional rate is defined as the amount oftorque required per degree of center hub rotation. There arethree basic categories of torsional rates for clutch dampers:rigid, standard, soft.

Rigid and Clutch Discs - Rigid discs and clutch discs with nospring package whatsoever, act as a nearly direct link from theengine flywheel to the transmission and offer no protectionagainst torsional vibration. Their use should be limited toolder mechanically-fueled engines where clutch replacement

cost is paramount over long component life. Rigid clutchdiscs are never used in new OEM applications.

Standard Dampers - Standard dampers include all 10-springand most 8- spring types. The springs used in these dampersare approximately 1.5" long and do not offer a large amount ofdeflection before coil lock takes place. While these damperswere completely adequate for most heavy duty applicationsseveral years ago, they are generally incapable of reducing theengine flywheel vibrations developed with slow speed elec-tronically fueled engines. The use of standard dampers inheavy duty applications has virtually ceased in OEM applica-tions. The trend is to use more capable soft-rate dampers.

Soft-Rate Dampers - Soft-rate dampers, like the heavy-duty7-spring and VCT Plus, offer much better protection againstengine flywheel induced torsional vibrations. Their springs arecharacteristically longer than springs used in standard ratedampers and offer more deflection before coil lock occurs.This larger spring deflection is equated to lower torsionalspring rate. With lower torsional rate, the resonant frequencyof the complete drivetrain is lowered; usually to a point of afew hundred RPM below normal engine operating range. Withthe addition of hysteresis or Coulomb dampening (the energyexpelled as the damper is exercised), the magnitude of the

vibrations is reduced further, adding to the dampers benefit.

Pre-Dampers - Pre-damper is a feature designed for reducingidle rattle noise in various applications, where torsional vibra-tions are growing more erratic. That is why Eaton is nowintroducing the latest option for heavy-duty applications, theVCT Plus PD, where PD stands for Pre-Damper. The Pre-Damper consists of seven small springs, surrounding the hubthat reduce idle rattle when operating at low torque or enginespeed with the transmission in neutral, prior to operation ofthe primary damper stage.


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General Information

Clutch Disc Friction Material

Organic facings, often called rag facings, get their namefrom the high concentration of organic rubber and binderagents that make up their composition. Fiberglass cord (orsimilar material) is woven into the material matrix and addsburst strength and improves friction and wear properties.Asbestos has not been used in organic friction material sincethe early 1980's. Organic facings are used without exceptionin passenger car and light truck applications. This is sobecause of smooth engagement properties and the relativelight torque loads imposed on the clutch. In general, organicfriction material lacks in performance in wear rate, coefficientof friction (ability to carry torque), and resistance to fade(abuse tolerance) when compared to cera-metallic frictionmaterial. The use of organic friction material in heavy vehicleshas significantly declined over the past decade. Wear life and

its maximum limit to 1,400 lb-ft. (1892 Nm) of torque in15.5" clutches are the primary reasons.

Cera-metallic (Ceramic) friction facings are composite mate-rial (copper, sand and other friction modifiers and binderagents). The dry raw materials are mixed in bulk, poured intodie cavities, compressed, sintered in an controlled atmo-sphere, then brazed into a steel backer plate to facilitate rivetattachment to the driven disc. Compared to organic frictionmaterial, cera-metallics have improved performance in theareas of wear rate, resistance to fade (abuse tolerance), andcoefficient of friction (ability to carry torque). It is for this rea-son that cera-metallics make up the vast majority of OEM

builds.

Clutch Slippage

Slippage will cause significant heat build-up and rapid wear ofthe clutch pack. If the clutch pack temperature raises beyondthe facing threshold temperature, the facing may disintegrate.Slippage is the result of loss of clamp load due to lack ofadjustment, loading the clutch beyond its design torque rat-ing, or the clutch has reached the end of its design life. Withthe ability to re-rate an electronic controlled diesel engine, it isquite easy to delivery torque to the clutch beyond its design

capacity. Before an engine re-rating is performed, confirm thatthe clutch and other drivetrain components are capable of car-rying the increased torque and power.

Clutch Torque Capacity

It is imperative to understand the factors that influence fric-tion force because this device transmits torque via friction.The fundamental equations that describes friction is:

F(f) = uN

Where F(f) = Force due to friction

U = Coefficient of friction

N = Load applied to the friction interface

T = F(f)r

Since torque (T) is equal to force friction F(f) multiplied by the

moment arm (R) (distance from application of force to centeror rotation) must be known. To exactly calculate the momentarm, the mean radius of a clutch (R), integration must be per-formed. However, for clutches in the size range offered byEaton, the calculation can be simplified to:

(r) = (ID + OD) / 4

Clutch Wear

Clutch wear happens because the clutch discs slip relative tothe engine flywheel and the pressure plate surface, and in the

case of a two plate clutch, the intermediate plate, during vehi-cle launch and gear change. As the clutch disc friction mate-rial and mating flywheel and pressure plate surfaces wear, thegage thickness of the clutch pack decreases (moving thepressure plate closer to the engine flywheel). This movementof the pressure plate causes the pressure spring(s) to elon-gate and loose clamping load. If clamping load is allowed todecrease beyond a critical point, the clutch will be unable tocarry full engine torque and slip.

Cover Assembly

The cover assembly, constructed of either stamped steel orcast iron, is bolted to the flywheel. It contains the pressureplate, which is fitted to the cover with pressure springs. It alsocontains the release bearing and levers, which move the pres-sure plate back and forth, thereby making or breaking contactwith the disc assembly.


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General Information

Factors that Effect Clutch Performance

Excessive slipping is the major cause of clutch failure.Extreme operating temperatures can cause the clutch to failbecause the heat generated between the flywheel, drivendiscs, intermediate plate, and pressure plate is high enough tocause the metal to flow and the friction material to bedestroyed.

An improperly adjusted or slipping clutch will produce suffi-cient heat to rapidly burn up.

There are many factors which have significant impact onclutch life:

Application (torque capacity)

GCW/Weight

Number of starts per day

Maintenance/Adjustment

1. Starting the Vehicle in the Proper Gear -The cor-rect gear will allow you to start the vehicle with yourfoot off the throttle.

2. Gear Shifting Techniques - Many drivers upshiftinto the next gear or even skip-shift into a highergear before the vehicle has reached the properspeed. This type of shifting is almost as damaging asstarting off in a gear that is too high, since theengine speed and vehicle speeds are too far apart,

requiring the clutch to absorb the speed differenceas heat.

3. Excessive Vehicle Overload or Overloading theClutch - Clutches are designed and recommendedfor specific vehicle applications and loads. Theselimitations should not be exceeded. Excessive orextreme overloading is not only damaging to theclutch but to the entire vehicle powertrain as well. Ifthe total gear reduction in the powertrain is not suffi-cient to handle excessive overloads, the clutch willsuffer, since it is forced to pick up the load at ahigher speed differential.

4. Do Not Ride the Clutch Pedal - Riding the clutch isvery destructive to the clutch since a partial clutchengagement permits slippage and excessive heat.Riding the clutch pedal will also put a constant thrustload on the release bearing, which can thin out thelubricant and also cause excessive wear on the pads.Release bearing failures can often be attributed tothis type of operation.

5. Do Not Slip the Clutch to Hold the Vehicle on anIncline - This procedure uses the clutch to do the job

normally expected of the wheel brakes. A slippingclutch accumulates heat faster than it can be dissi-pated, resulting in early failures.

6. Do Not Coast with the Clutch Released and Trans-mission in Gear - This procedure can cause highdriven disc RPM through multiplication of ratiosfrom the final drive and transmission. It can result inthrowing the facing off the clutch discs. Drivendisc speeds of over 10,000 RPM have been encoun-tered in such simple procedures as coasting tractorsdown an unloading ramp. While an ample safety fac-tor is provided for normal operation, the burststrength of the facing is limited.

7. Do Not Engage the Clutch while Coasting -This

procedure can result in tremendous

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