Manual de Servicio 02 EATON PDF

Eaton Fuller Clutches
Solo Heavy Duty 15.5" Solo Medium Duty 14" 1401 and 1402 Easy Pedal Plus 14 " Easy Pedal 2000 15.5" Stamped Angle Spring
Service Manual CLSM -1282
October 2002
For the most current information, visit the Roadranger web site at www.roadranger.com
General Information
Notes, Cautions, and Warnings

WARNING: Follow the specified procedures in the indicated order to avoid personal injury. CAUTION: Follow the specified procedures in the indicated order to avoid equipment malfunction or damage. Note: Additional relevant information not covered in the service procedure. Use of other than recommended tools, parts, and instructions listed in this manual may place the safety of the service technician or vehicle driver in jeopardy. The removal and installation procedure described for each component may vary for your vehicle. For service information and assistance anywhere in North America please call 1-800-826-4357, 24-hours a day. Phone lines are manned by leading specialists in the areas of engineering, marketing, distribution, troubleshooting, product specification, installation and maintenance. You may also find more information about Eaton Fuller Clutches on our web site: www.roadranger.com. Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation makes no warranty, expressed or implied, based on the information provided.
Repair Warnings
The major cause of clutch failure is excessive heat. Excessive heat generated between the flywheel, driven discs, intermediate plate and pressure plate can cause the metal to flow and the material to be destroyed. If this occurs, the clutch can burst which can cause property damage, serious bodily injury or death. In order to prevent clutch failure resulting from excessive heat: 1. 2. 3. 4. Do not exceed recommended vehicle loads. The clutch should only be used for the recommended applications. Drivers should be properly trained in starting, shifting and operation of the clutch. Drivers should report erratic clutch operation as soon as possible to permit maintenance personnel to inspect, adjust or lubricate as required. Mechanics must be familiar with proper clutch adjustment, linkage adjustment, lubrication and other maintenance troubleshooting procedures outlined in the Failure Analysis Guide and the Eaton Fuller Solo Clutch Troubleshooting Guides.
5.
When disassembling various assemblies, lay all parts on a clean bench in the same sequence as removed to simplify and reduce the possibility of losing parts. Since the cost of a new part is generally a small fraction of the cost of downtime and labor, avoid reusing a questionable part that could lead to additional repairs and expense.
Table of Contents
Introduction
Preventive Maintenance Overview .............................................................................................................................. 1 Designing a Clutch for a Specific Application ............................................................................................................. 3 Function of a Clutch ................................................................................................................................................... 4 Factors that Effect Clutch Performance ...................................................................................................................... 8
Service Procedures
Eaton Fuller Solo Heavy Duty 15.5" Clutches ............................................................................................................ 11 Solo Heavy Duty 15.5" Clutch - Remove .................................................................................................................. 13 Solo Heavy Duty 15.5" Clutch - Install ...................................................................................................................... 15 Eaton Fuller Solo Medium Duty 1401 Clutches ........................................................................................................ 25 Solo Medium Duty 1401 Clutch - Remove ............................................................................................................... 27 Solo Medium Duty 1401 Clutch - Install .................................................................................................................. 29 Eaton Fuller Solo Medium Duty 1402 Clutches ........................................................................................................ 37 Solo Medium Duty 1402 Clutch - Remove ............................................................................................................... 39 Solo Medium Duty 1402 Clutch - Install .................................................................................................................. 41 Eaton Fuller Easy Pedal 15.5" Clutches ..................................................................................................................... 51 Easy Pedal 15.5" Clutch - Remove ........................................................................................................................... 53 Easy Pedal 15.5" Clutch - Install ............................................................................................................................... 55 Eaton Fuller Easy Pedal Plus 14" Clutches ................................................................................................................ 65 Easy Pedal 14" Clutch - Remove .............................................................................................................................. 67 Easy Pedal 14" Clutch - Install .................................................................................................................................. 69 Eaton Fuller Stamped Angle Spring 1401 Clutches .................................................................................................. 79 Stamped Angle Spring 1401 Clutch - Remove ......................................................................................................... 81 Stamped Angle Spring 1401 Clutch - Install ............................................................................................................ 83 Eaton Fuller Stamped Angle Spring 1402 Clutches .................................................................................................. 91 Stamped Angle Spring 1402 Clutch - Remove ......................................................................................................... 93 Stamped Angle Spring 1402 Clutch - Install ............................................................................................................ 95 Heavy Duty Resetting Overview ............................................................................................................................. 103 Solo Heavy Duty Clutch - Resetting ....................................................................................................................... 105 Medium Duty Resetting Overview .......................................................................................................................... 107 Medium Duty Solo Clutch - Resetting .................................................................................................................... 109
Table of Contents
Preventive Maintenance
Preventive Maintenance Overview

To ensure long life and proper operation of the release mechanism of the clutch, it is important to properly lubricate the following areas.
Lube Tube Assembly

The Eaton Fuller Lube Tube Assembly enables the release bearings in Eaton Fuller medium and heavy duty clutches to be greased without removing the bell housing inspection cover. The Lube Tube Hose replaces the original zerk fitting on the release bearing and protrudes through the bell housing window.
Lubrication
1. Release Bearing- The cast iron bearing housing will be equipped with either a standard grease fitting or a lube tube extension. If a lube tube is not present, it is necessary to remove the inspection cover to gain access to the grease fitting. Apply grease until it purges from the rear of the housing. Grease on the clutch brake friction surface and the transmission input shaft will extend the life of the clutch brake and bronze bushings inside the release sleeve. Release Bearing Wear Pads- Where the release fork contacts the bearing housing, there are small hardened steel pads. Apply a small amount of grease to the wear pads where the clutch release fork contacts. Clutch Brake- The clutch brake friction material is designed to operate with lubricant. While lubricating the release bearing, grease should purge from the housing and contact the clutch brake. This is beneficial for long clutch brake life. If desired, a small amount of grease could be applied to both sides of the clutch brake. Cross-Shaft Bushings- Lubricate both the left and the right cross-shaft bushings per OEM recommendations. Clutch Control Linkage- Lubricate the clutch linkage bell cranks and pivot pins per OEM recommendations. Pilot Bearing- The pilot bearing inside the flywheel is a sealed for life bearing and requires no lubrication. Use a premium pilot bearing to prevent clutch drag and early bearing failures. (C-3, C-4, C-5 Suffix)
Lube Tube Lengths

Length in Inches 12" 9" 8" 7" 6" Part Number CLT012 CLT009 CLT008 CLT007 CLT006
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3.
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6.
Preventive Maintenance
Recommended Lubrication
Use a lithium soap base E.P. (Extreme Pressure) grease with a minimum of +325 degree F operating range. It must meet the N.L.G.I.s Grade 1 or 2 specs. CAUTION: Incorrect grease and improper lube procedures will cause bearing failures, bushing wearout, yoke tip and bearing wear pad wear.
Lubrication Interval
Sealed Type
With the Solo Maintenance-Free Clutch, there is no need for lubrication. The following information does not apply.
Greasable Type
Stamped Angle Spring 1401 and 1402 Solo Medium Duty 1401 and 1402 On-Highway - Every 10,000 miles (16,000 Km) or once per month. Off highway/severe service - Every 250 hours or once per month.
Supplier American Oil Co. City Service Co. Fiske Refining Co. Keystone Lubricating Co. Mobil Humble Oil Co. Atlantic Richfield Co. Texaco Shell Oil Co. Shell Oil Co. *Chevron Oil Co. *Texaco *Exxon
Product Amoco Uthium-M.P. Grease Citgo Premium Lithium Grease #2 Lubnplate 630-2 #81 Ught Mobilgrease M.P. Udok 2 Arco M.P. Multifak #2 Retinax A Aivania #2 S.R.I. 1~ Premium RB Unirex N3
Solo Heavy Duty On-Highway - Every 25,000 miles (40,000 Km) or once per month [Solo XL = 50,000 miles (80,000 Km)].
General Information
Off highway/severe service - Every 250 hours or once per month.
Easy-Pedal Plus 14 and Easy-Pedal 2000 15.5 On-Highway - Every 20,000 miles (32,186 Km) or once per month. Off highway/severe service - Every 250 hours or once per month.
* Approved for vendor prepack, other greases listed are for service only.
For additional lubrication information See TCMT-0021 or call 1-800-826-HELP (4357).
General Information
Designing a Clutch for a Specific Application

There are three parts to designing a clutch for a specific application. If the correct clutch is chosen, the truck will have good engagement, protection for the driveline, long clutch life, and minimal loss of torque. 1. Check the Flywheel Bore (15.5" Clutch) - The flywheel environment must be checked to make sure a clutch can be used with it. The bore is important when deciding what type of driven disc to use. The bore must be large enough to allow for a proper fit of the disc. See chart below.
Measure bore size
Engine Flywheel
# of Springs Bore size 8 spring 7 1/4" (184.15mm) 10 spring 8 9/16" (217.48mm) 7 spring 9 3/4" (247.65mm) (247.65mm) 9 spring(Mack eng only) 9 3/4" 6 spring 9 3/4" (247.65mm)
2.
Torque Capacity - A clutch must be chosen that has a torque capacity that is greater than or equal to the peak torque of the engine. This is very important today when an engine can be easily adjusted electronically to produce greater torque. There are two factors in determining torque capacity. These two factors are friction force and damper capacity. Friction force is a product of the cover assemblies clamp load (also called plate load). This factor was explained in the previous section, and is stated as F(f) = uNPr. Determining the friction force is important because if this force is not greater than or equal to the peak torque of the engine, the clutch will slip. Damper capacity is what allows the clutch to provide torsional protection for the entire driveline. If the peak engine torque exceeds this capacity, the driveline will be abused. This abuse will cause faster wear and possible destruction of driveline components. Since damper capacity is a product of the springs used in the damper, changing the number and type of springs changes the stiffness of the entire system.
3.
Application - Service replacement clutches should have the same plate loads, damper and friction material. Substituting from the original could shorten the life of the clutch and drivetrain components.
General Information
Function of a Clutch
Any modern day clutch, whether designed for an automobile or heavy truck, performs several important tasks allowing for safe and convenient operation of the vehicle. In a vehicle powertrain, the clutch is the device that interrupts the flow of power from the engine flywheel to the transmission. To start a gasoline or diesel engine, the flywheel must be able to turn freely without propelling the vehicle. By disengaging the clutch, the drivetrain is effectively disconnected from the 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 gear change, the clutch pedal is depressed, breaking toque. This is followed by altering engine speed to more closely match the transmission input shaft (clutch disc) speed. After the proper gear is selected, the clutch pedal is then slowly released. As the clutch disc(s) are compressed, the relative slip speed between the flywheel and the transmission input shaft reaches zero and the clutch is completely engaged and capable of carrying full engine torque. With non-synchronized gearboxes, double clutching (a momentary partial engagement of the clutch made while the transmission is in neutral) is often necessary to allow rotational speeds of gears to become the same and complete the gear change. With the advent of transmission automation, breaking torque and altering flywheel speed is accomplished via electronic throttle control and engine braking. The clutch pedal is used only when starting the engine, launching the vehicle from a stop, and when the vehicle slows to a stop. The last function of the clutch is mitigating torsional vibrations. With any in-line, six-cylinder engine there are three (3) distinct power pulses occurring during each revolution of the flywheel. With each firing of a cylinder, the flywheel speeds up then slows down, very quickly, resulting in a torsional vibration. This vibration can damage drivetrain components in short order if left uncontrolled. The coil springs in a driven disc damper absorb much of the vibration. The resonant (generally the least expensive drivetrain component) is considered the fuse of the system. Failure of a clutch damper section is usually an indication of a serious torsional vibration systems problem or shock loading due to driver abuse. Clutches are assemblies made up of many different components utilizing many different types of materials. This section describes the major components which make up a complete Eaton Fuller Clutch installation. The following are the major components used to make up a clutch installation: Cover Assembly (contains pressure plate) Intermediate Plate (only in 2-plate clutches) Driven Disc(s) Clutch Brake
Solo Clutches
The Eaton Fuller Solo is the industrys first adjustment-free clutch. With every push of the pedal, Solos innovative wearadjusting technology senses for wear and makes any adjustments necessary.
Why There is No Need to Adjust Eaton Fuller Solo Clutches

If the Solo Clutch is properly installed and the linkage is setup properly, the Solo Clutch should never need internal or external adjusting. The Solo Clutch automatically keeps the proper release bearing position and clutch free pedal position with two opposing cams. As the Solo Clutch wears, the cams separate from each other keeping the proper release bearing position. This in turn maintains the proper clutch free pedal position.
General Information
How it Works
Eaton Fuller Solos wear-adjusting technology comes from two sliding cams. With every push of the pedal, the clutch senses for wear and makes any adjustments necessary. The cams rotate to maintain the proper adjustment throughout the life of the clutch. On top of the upper cam, a clutch wear indicating tab mirrors the cams movement to let you know when its time to replace the clutch. The result of Solos constant adjustment is greater longevity and a reduction in maintenance and labor costs.
General Information
Clutch Disc Dampening Characteristics

A key function of a clutch is to mitigate naturally occurring vibrations of the engine flywheel from reaching the transmission and the other components further down the drivetrain. This is accomplished by employing torsional spring dampers to 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 damper begins at the friction, interface at the facings, proceeds to the steel carrier disc and moves into the disc reinforcing plates where the springs are located. The springs are compressed, transmitting force to the spring covers which are rigidly attached to the hub. Torsional rate is defined as the amount of torque required per degree of center hub rotation. There are three basic categories of torsional rates for clutch dampers: rigid, standard, soft. Rigid and Clutch Discs - Rigid discs and clutch discs with no spring package whatsoever, act as a nearly direct link from the engine flywheel to the transmission and offer no protection against torsional vibration. Their use should be limited to older mechanically-fueled engines where clutch replacement cost is paramount over long component life. Rigid clutch discs are never used in new OEM applications. Standard Dampers - Standard dampers include all 10-spring and most 8- spring types. The springs used in these dampers are approximately 1.5" long and do not offer a large amount of deflection before coil lock takes place. While these dampers were completely adequate for most heavy duty applications several years ago, they are generally incapable of reducing the engine flywheel vibrations developed with slow speed electronically fueled engines. The use of standard dampers in heavy duty applications has virtually ceased in OEM applications. The trend is to use more capable soft-rate dampers. Soft-Rate Dampers - Soft-rate dampers, like the heavy duty 6 and 7-spring types, offer much better protection against engine flywheel induced torsional vibration. Their springs are characteristically longer than springs used in standard rate dampers and offer more deflection before coil lock occurs. This larger spring deflection is equated to lower torsional spring rate. With lower torsional rate, the resonant frequency of the complete drivetrain is lowered; usually to a point of a few hundred RPM below normal engine operating range. With the addition of hysteresis or Coulomb dampening (the energy expelled as the damper is exercised), the magnitude of the vibrations is reduced further, adding to the dampers benefit.
Clutch Disc Friction Material

Organic facings, often called rag facings, get their name from the high concentration of organic rubber and binder agents that make up their composition. Fiberglass cord (or similar material) is woven into the material matrix and adds burst strength and improves friction and wear properties. Asbestos has not been used in organic friction material since the early 1980's. Organic facings are used without exception in passenger car and light truck applications. This is so because of smooth engagement properties and the relative light torque loads imposed on the clutch. In general, organic friction material lacks in performance in wear rate, coefficient of friction (ability to carry torque), and resistance to fade (abuse tolerance) when compared to cera-metallic friction material. The use of organic friction material in heavy vehicles has significantly declined over the past decade. Wear life and its maximum limit to 1,400 ft. lbs. (1892 Nm) of torque in 15.5" clutches are the primary reasons. Cera-metallic (Ceramic) friction facings are composite material (copper, sand and other friction modifiers and binder agents). The dry raw materials are mixed in bulk, poured into die cavities, compressed, sintered in an controlled atmosphere, then brazed into a steel backer plate to facilitate rivet attachment to the driven disc. Compared to organic friction material, cera-metallics have improved performance in the areas of wear rate, resistance to fade (abuse tolerance), and coefficient of friction (ability to carry torque). It is for this reason that cera-metallics make up the vast majority of OEM builds.
Clutch Slippage
Slippage will cause significant heat build-up and rapid wear of the clutch pack. If the clutch pack temperature raises beyond the facing threshold temperature, the facing may disintegrate. Slippage is the result of loss of clamp load due to lack of adjustment, loading the clutch beyond its design torque rating, or the clutch has reached the end of its design life. With the ability to re-rate an electronic controlled diesel engine, it is quite easy to delivery torque to the clutch beyond its design capacity. Before an engine re-rating is performed, confirm that the clutch and other drivetrain components are capable of carrying the increased torque and power.
General Information
Clutch Torque Capacity

It is imperative to understand the factors that influence friction 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 center or rotation) must be known. To exactly calculate the moment arm, the mean radius of a clutch (R), integration must be performed. However, for clutches in the size range offered by Eaton, the calculation can be simplified to: (r) = (ID + OD) / 4
Driven Disc
Eaton offers a variety of 14" and 15.5" driven disc designs. The selection of driven discs depends on many factors. Excessive torsional vibration can significantly reduce the life of all drivetrain components. Thats why Eaton has engineered soft-rate dampers to reduce critical vibrations in todays electronic, high horsepower engines. Eaton recommends the use of soft-rate dampers (7-spring or 6-spring V.C.T.) for all vehicles over 1,000 ft. lbs. Specifically, Eaton offers driven discs with different numbers of springs in the center section of the damper. 6, 7, 8, 9 and 10-spring configurations are available. The proper selection depends on many factors including the engine, flywheel and transmission of the vehicle.
Facings
The disc facings are critical to clutch life and performance because they directly receive the torque of the engine each time the clutch is engaged. In general, ceramic facings have greater heat tolerance and torque capacity than organic facings. As such, they engage quicker, reduce slippage and deliver longer life. Organic facings (non-asbestos) are adequate for lower horsepower, on-highway applications. However, Eaton recommends ceramic facings for most applications.
General Information
Clutch Wear
Clutch wear happens because the clutch discs slip relative to the engine flywheel and the pressure plate surface, and in the case of a two plate clutch, the intermediate plate, during vehicle launch and gear change. As the clutch disc friction material and mating flywheel and pressure plate surfaces wear, the gage thickness of the clutch pack decreases (moving the pressure plate closer to the engine flywheel). This movement of the pressure plate causes the pressure spring(s) to elongate and loose clamping load. If clamping load is allowed to decrease beyond a critical point, the clutch will be unable to carry full engine torque and slip.
Intermediate Plate
The intermediate plate or center plate, increases the torque capacity of the clutch by providing additional surface area for facing material and torque capacity. The intermediate plate is driven by the clutch cover or by the flywheel on the 14" EasyPedal Plus design.
Cover Assembly
The cover assembly, constructed of either stamped steel or cast iron, is bolted to the flywheel. It contains the pressure plate, which is fitted to the cover with pressure springs. It also contains the release bearing and levers, which move the pressure plate back and forth, thereby making or breaking contact with the disc assembly.
Positive Separator Pin

Eaton Fullers Positive Pin Separator improves clutch life and performance by providing cooler operation, smoother engagement and equal plate separation. The pin restricts intermediate plate movement when the clutch is released, giving constant gap on both sides of the plate, therefore, allowing the driven discs to spin freely.
General Information
6-Position Kwik-Adjust
Eaton Fullers Easy-Pedal Plus 14" and Easy-Pedal 2000 15.5" Clutches feature the Kwik-Adjust component and the easy-to-reach external manual adjustment mechanism that allows for quick adjustment of release bearing travel without the use of special tools or the need to remove any bolts. Using a common box end wrench, simply depress the Kwik-Adjust bolt and turn the standard 6-point hex head adjustor as needed.
Torque Limiting Clutch Brake

The Eaton Fuller Torque Limiting Clutch Brake has a self-contained torque limiting feature which prevents tang breakage from driver misuse of the clutch brake. 127740: 1.75" spline 127760: 2" spline
Kwik-Konnect Two-Piece Clutch Brake

The two-piece clutch brake provides cooler operation than competitive clutch brakes. It is designed for service applications, and can be quickly installed without removing the transmission.
Clutch Brakes
Clutch brakes are designed to extend the life of a vehicles transmission by eliminating damaging gear clash while reducing the effort required to shift into first or reverse from a standstill. Eaton offers two separate clutch brake options. Torque Limiting Kwik-Konnect
General Information
Factors that Effect Clutch Performance

Excessive slipping is the major cause of clutch failure. Extreme operating temperatures can cause the clutch to fail because the heat generated between the flywheel, driven discs, intermediate plate, and pressure plate is high enough to cause the metal to flow and the friction material to be destroyed. An improperly adjusted or slipping clutch will produce sufficient heat to rapidly burn up. There are many factors which have significant impact on clutch life: 1. Application (torque capacity) GCW/Weight Number of starts per day Maintenance/Adjustment Starting the Vehicle in the Proper Gear - The correct gear will allow you to start the vehicle with your foot off the throttle. Gear Shifting Techniques - Many drivers upshift into the next gear or even skip-shift into a higher gear before the vehicle has reached the proper speed. This type of shifting is almost as damaging as starting off in a gear that is too high, since the engine speed and vehicle speeds are too far apart, requiring the clutch to absorb the speed difference as heat. Excessive Vehicle Overload or Overloading the Clutch - Clutches are designed and recommended for specific vehicle applications and loads. These limitations should not be exceeded. Excessive or extreme overloading is not only damaging to the clutch but to the entire vehicle powertrain as well. If the total gear reduction in the powertrain is not sufficient to handle excessive overloads, the clutch will suffer, since it is forced to pick up the load at a higher speed differential. Do Not Ride the Clutch Pedal - Riding the clutch is very destructive to the clutch since a partial clutch engagement permits slippage and excessive heat. Riding the clutch pedal will also put a constant thrust load on the release bearing, which can thin out the lubricant and also cause excessive wear on the pads. Release bearing failures can often be attributed to this type of operation. Do Not Slip the Clutch to Hold the Vehicle on an Incline - This procedure uses the clutch to do the job 8 8. 7. normally expected of the wheel brakes. A slipping clutch accumulates heat faster than it can be dissipated, resulting in early failures. 6. Do Not Coast with the Clutch Released and Transmission in Gear - This procedure can cause high driven disc RPM through multiplication of ratios from the final drive and transmission. It can result in throwing the facing off the clutch discs. Driven disc speeds of over 10,000 RPM have been encountered in such simple procedures as coasting tractors down an unloading ramp. While an ample safety factor is provided for normal operation, the burst strength of the facing is limited. Do Not Engage the Clutch while Coasting - This procedure can result in tremendous shock loads and possible damage to the clutch, as well as the entire drivetrain. Reporting Erratic Clutch Operation Promptly - Drivers should report erratic clutch operation as soon as possible, to give the maintenance personnel a chance to make the necessary inspection, internal clutch adjustment, linkage adjustment and lubrications, thereby avoiding possible clutch failures and breakdowns while on the road. The importance of free pedal travel (sometimes referred to as a pedal lash) should be brought to the drivers attention as well as the mechanic. This item should be included and commented on daily in the drivers report, since clutch free pedal is the maintenance personnels guide to the condition of the clutch and the release mechanism. Clutch Adjustments - Manual Adjustment- The importance of proper and timely clutch adjustments and lubrication can not be over stated. Internally adjusting the clutch properly and when needed will keep the clutch components in the proper position and extend the life of the clutch. See the adjustment section for more information. Solo Adjustmen-Free If your truck is equipped with an Eaton Fuller Solo Adjustment-Free Clutch, then the clutch will always be in proper adjustment. Possible lubrication and inspection are needed. See Inspection and Lubrication.
General Information
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General Information
When to Inspect the Clutch

The clutch should be inspected during the regularly scheduled lubrication intervals as dictated in the Lubrication section or when one of the following occur: Clutch Free Pedal - If the clutch free pedal is onehalf of OEM specifications, not less than one-half inch. During normal clutch use, the release bearing will move toward the fork fingers and reduce in cab free pedal. Clutch Is Slipping - If the clutch is slipping, it may require adjustment. If proper internal (clutch adjuster) and external (clutch linkage) adjustment has been made and the clutch still slips, it is likely worn beyond its useful life and needs replacement.
Inspection for Clutch Life

If your vehicle is equipped with a Eaton Fuller Solo or Solo XL (Extended Lube) Clutch, the clutch is equipped with a clutch wear indicating tab that can be seen through the inspection window. To calculate the expected life of a Solo, apply a paint mark indicating the start point of the clutch wear indicating tab. Record the mileage when this mark was made. After a few months, reinspect the position of the clutch wear indicating tab and record the new mileage. The difference between the two readings can be used to estimate when the clutch will need to be replaced.
For Example:
Starting Mileage = 10,000 After six (6) months mileage = 75,000 Clutch wear indicating tab movement = .625" (16 mm) 75,000-10,000 = 65,000 miles 65,000 miles/.625" = 104,000 miles per inch of tab movement 3.5" remaining tab movement 3.5" remaining tab movement X 104,000 miles per inch of tab movement = 364,000 expected clutch life.
General Information
General Information
10
Service Procedure
Eaton Fuller Solo Heavy Duty 15.5" Clutches

Special Instructions
Eaton Fuller Solo XL and Maintenance-Free Clutches require a specially designed release yoke (97-509-10-1X). The Roller Yoke can only be used with Solo XL and Maintenance-Free type clutches. Eaton recommends that any time a new Solo Maintenance-Free Clutch or a Solo Extended Lube Clutch is installed that a new roller yoke also be installed. Eaton Fuller service part numbers 109705-xxY 109706-xxY and 109710xxY include the roller yoke. Eaton Fuller Standard Heavy Duty Solo 109701-xx uses a standard yoke 105C137 or equivalent. Note the position of the wear indicating tab on the clutch. If the tab is near the "REPLACE" position, the clutch should be replaced. CAUTION: When fully assembled, the 15.5" clutch weighs approximately 150 pounds (68 kg). A hydraulic clutch jack is recommended.
Required Tools
Basic Hand Tools Clutch Jack
Essential Steps
If a Solo Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (7/16" x 14 UNC x 1- 3/4"). Verify diameter of the flywheel bore (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening. 10-spring driven discs require 8.56" (219 mm) dia. (minimum) 6-spring (V.C.T.) driven discs require 9.75" (248 mm) dia. (minimum) 7-spring driven discs require 9.75" (248 mm) dia. (minimum) 9-spring driven discs require 9.75" (248 mm dia. (minimum) (Mack Engines Only)
Specifications
Use C3 - C4 Pilot Bearing Torque clutch to flywheel mounting bolts 4050 ft. lbs. (54-68 Nm)
ENGINE
Clutch
Transmission
11
Service Procedure
EP
R ES
S BOLT
Clutch Exploded View
Driven Disc Driven Disc
Clutch Assembly
T
O
Service Procedure
TU R
Engine Flywheel Intermediate Plate
Flywheel bore
12
Service Procedure
Solo Heavy Duty 15.5" Clutch - Remove

Procedure1. Remove the transmission, supporting its weight to prevent damage to the bearing and discs. Note: If a Solo Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (7/16" x 14 UNC x 1- 3/4"). 2. Locate four (4) 7/16" x 14 x 1- 3/4" UNC, hex head machine screws. Install them in the 4 cover holes, turning them one complete turn after they contact the cover. Remove the clutch from the flywheel. Note: Mark the proper position of the discs and intermediate plate (for reinstallation).
3.
13
Service Procedure
1
Remove the Transmission
2
Locate 4 Hex Head Machine Screws
(4) 7/16" x 14 x 1-3/4" UNC
Service Procedure
Solo Heavy Duty 15.5 Clutch Removal
14
Service Procedure
Solo Heavy Duty 15.5" Clutch - Install

Procedure1. Remove the old pilot bearing and wipe all surfaces that will contact the gauging. Secure the dial indicator to the flywheel housing with the gauge finger near the outer edge of the flywheel. 8. 3. Use a soapstone to mark the high and low spots as you rotate the flywheel one (1) revolution. The difference between these two spots should be .008" (0.2 mm) or less. With the dial indicator still secured to the flywheel housing, continue the inspection process by moving the gauge finger so it contacts the pilot bearing bore surface. Rotate the flywheel one (1) revolution. The maximum allowed run out must be .005" (0.13 mm). Secure the dial indicator to the crankshaft with the gauge finger against the flywheel housing pilot area. 7. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2mm) or less. Secure the dial indicator to the flywheels outer diameter and move the gauge finger until it contacts the face of the flywheel housing. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2mm) or less. CAUTION: If the above four (4) limits are exceeded, the problem must be corrected. Misalignment will cause damper failure and wear to drivetrain components. 10. Install a new pilot bearing. Eaton strongly recommends the use of a premium grade pilot bearing. The bearing must have a press fit. CAUTION: Tap on the outer race only. Tapping the inner race could cause damage to the pilot bearing.
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6.
15
Service Procedure
1
Wipe All Surfaces That Will Contact Gauging
2
Secure Indicator to Flywheel Housing
3
Use a Soapstone to Mark High and Low Spots
4
Place Gauge Finger in Contact With Pilot Bearing Bore
6
Secure the Dial Indicator to Crankshaft Service Procedure
5
Rotate Flywheel One Revolution
7
Mark High and Low Spots While Rotating Flywheel One Turn
10
Install a New Pilot Bearing
8
Secure Dial Indicator to Flywheels Outer Diameter
9
16
Heavy Duty 15.5 Clutch Installation
Service Procedure
Solo Heavy Duty 15.5" Clutch - Install, Cont

11. Check the following items for wear and replace any worn components: a. Cross-shafts and bushings 13. Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening. Note: Excessive wear at these points can cause a side loading condition onto the sleeve bushing of the newly installed Solo Clutch. Consequently, this condition can cause the bushing to walk-out of the sleeve. Also, inspect the remaining pivot points of the linkage for excessive wear. b. c. Release yoke fingers Transmission bearing retainer cap 10-spring driven discs require 8.56" (219 mm) dia. (minimum) 6-spring (V.C.T.) driven discs require 9.75" (248 mm) dia. (minimum) 7-spring driven discs require 9.75" (248 mm) dia. (minimum) 9-spring driven discs require 9.75" (248 mm) (Mack Engines Only)
Note: A worn/rough bearing retainer cap may cause the newly installed clutch brake to wear prematurely. Also, excess wear at either the transmission bearing retainer cap (arrow C) and/or the release yoke fingers (arrow B) may prevent the linkage from obtaining a suffcient amount of clutch brake squeeze (Recommended range is 1/2" 1" (13 24 mm). Refer to arrow G concerning the nominal distance between the input shafts end and the bearing retainer cap. d. Splines on the input shaft
Note: Any wear on the splines will prevent the newly installed driven discs from sliding freely, thus causing poor release (clutch drag). Select a disc out of the new installation and slide it full length on the transmission splines. This will detect a twisted input shaft. Replace input shaft if disc does not freely slide. e. Smooth area of input shaft
Note: Wear/roughness in this area can cause the sleeve bushing of the newly installed Solo to walk-out after only a few miles of operation. f. Mating surfaces
Note: Inspect the mating surfaces of both the transmission bell housing and the flywheel housing. Any appreciable wear on either housing will cause misalignment. Most wear will occur between the 3 and 8 oclock positions. Replace housings if worn. 12. Install a new Eaton Fuller Clutch Brake at this time.
17
Service Procedure
11A Check Cross-Shafts and Bushings
11B Check Release Yoke Fingers
11C Check Transmission Bearing Retainer Cap
Service Procedure
11D Check Splines on the Input Shaft
11E Check Smooth Area of Input Shaft for Wear/Roughness Solo Heavy Duty 15.5 Clutch Installation
18
Service Procedure

14. Insert two (2) 7/6" x I4 UNC x 5" (127 mm) long guide studs into the two upper mounting holes of the flywheel. 15. Insert the aligning tool through the release bearing sleeve of the new clutch. Note: With the Solo Maintenance-Free Clutch, place input shaft sleeve on alignment shaft. 16. Make sure to position one of the driven discs onto the aligning tool with the stamp Intermediate Plate Side facing the intermediate plate. Note: Steps 16 and 18 show the specific procedures for installing our 7-spring driven discs. When installing either the 9- or 10-spring driven discs, follow the instructions stamped on the front and rear discs to ensure their proper orientation toward the flywheel (front disc) and pressure plate (rear disc). Installing the disc(s) backwards or switching the front and rear discs with each other will prevent the clutch from functioning properly (i.e. does not release or cannot obtain proper adjustment). The 6-spring driven disc does not require any special orientation because: 1.) The front and rear discs are the same part number and 2.) These discs are symmetrical (mirror image). As a result, there are no instructions (concerning disc orientation) stamped on the 6-spring drive disc. 17. With the stamp Flywheel Side facing the flywheel, place the intermediate plate into the four (4) slots of the clutch cover. 18. Make sure to position the second driven disc onto the aligning tool with the stamp Intermediate Plate Side facing the intermediate plate. WARNING: When fully assembled, the 15.5" clutch weighs approximately 150 pounds (68 kg). A hydraulic clutch jack is recommended. 19. Position the clutch over the two (2) guide studs and slide it forward until contact is made with the flywheel surface. Note: Be sure that the aligning tool pilot is inserted into the pilot bearing. Failure to do this may result in the driven discs not being centered, causing difficult transmission installation.
19
Service Procedure
14
Insert 2 Guide Studs
15
Insert the Aligning Tool Through Release Bearing Sleeve
Guide Studs
Service Procedure
16
Place Disc on Aligning Tool Properly Orientated
17
Place Intermediate Plate Properly Orientated
18
Place Second Disc on Aligning Tool Properly Orientated Solo Heavy Duty 15.5" Clutch Installation
19
Place Clutch Over 2 Guide Studs and Slide Forward
20
Service Procedure

20. Start six (6) 7/16" x 14 UNC x 2 1/4" (57 mm) Grade 5 or better mounting bolts with lock washers and tighten them finger-tight. Remove the two (2) guide studs and replace them with the two (2) remaining mounting bolts/ lock washers. 21. Starting with the lower left-hand bolt, progressively tighten the eight (8) mounting bolts in a criss-cross pattern until you achieve a final torque of 4050 ft. lbs. (5468 Nm). CAUTION: Failure to tighten these bolts in this manner can: Prevent the clutch cover from centering into the pilot area of the flywheel. Cause permanent damage to the clutch cover (i.e. become cracked or broken). Cause the clutch assembly to be out-of balance with the flywheel. 24. Using a 1/4" (6 mm) diameter flat nose punch, lightly tap each of the four (4) Positive Separator Pins toward the flywheel. Performing this step will verify that all four (4) pins are flush against the flywheel. Note: Failure to perform this step properly may cause the clutch to drag (clutch does not release). Excessive force can damage the pins and cause a release problem. Note: The four (4) pins can also be set through the inspection opening of the transmission bell housing if they were not to set prior to transmission installation.
22. Remove the four (4) yellow colored shipping bolts in a criss-cross pattern. Note: Save these four (4) bolts for future use in case you need to remove, then reinstall the Solo Clutch. 23. Remove the aligning tool.
21
Service Procedure
20
Start 6 Mounting Bolts and Replace the 2 Guide Bolts
21
Tighten Mounting Bolts in a CrissCrossing Manner
6 4 8
21
Torque Mounting Bolts to 40-50 ft. lbs.
2
7 3
Service Procedure
22
Remove the 4 Shipping Bolts
23
Remove Aligning Tool
24
Tap Separator Pins Until Flush Against Flywheel Solo Heavy Duty 15.5" Clutch Installation
22
Service Procedure

25. Shift the transmission into gear and verify that a new Eaton Fuller Clutch Brake has been installed. 26. Position the transmission so that it is both square to and aligned with the engine. 27. While moving the transmission forward, rotate the output shaft of the transmission until the splines of both the input shaft and the disc(s) mesh with each other. While performing this task, you must also ensure that the yoke fingers remain in the up position until they can be rotated over the release bearing housing into their final position. Note: Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position. Doing so may release the clutch and overstroke the release bearing. The Solo will incorrectly set the release bearing position too close to the transmission and cause the wear indicating tab to move to 1/31/2 the distance towards the REPLACE position. Note: Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and make any necessary changes. Note: If the input shaft will not slide into the discs, they may need to be repositioned. If the clutch is to be unbolted from the flywheel, re-install the shipping bolts and tighten one turn past contact with the clutch. Now the installation shaft can be installed to reposition the discs and the clutch bolts retorqued. Remove the shipping bolts to clamp the discs. Note: Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch will not release. 28. Install the transmission mounting bolts and torque to the proper specification. 29. Adjust the linkage until the fingers of the release yoke contact the release bearing wear pads. You should have zero free play at the clutch pedal when this step has been completed. 30. Fully depress the clutch pedal a minimum of five (5) times. As a result, you should gain free play at the clutch pedal and the wear indicating tab on the clutch should slightly move away from the NEW position. 31. If the release bearing does not squeeze the clutch brake when the pedal is down, adjust the linkage to move the yoke to zero clearance and depress the pedal five (5) times. Note: With the pedal up, the release bearing should be .490" .560" (12.4 14.2 mm) from the clutch brake when properly set up. With the pedal down, contacting the clutch brake ensures: 1. 2. The Solo has adjusted fully to its new environment. The linkage is capable of pulling the bearing far enough to obtain clutch brake squeeze.
23
Service Procedure
25
Shift the Transmission into Gear
26
Align the Transmission with the Engine
SHIFT INTO GEAR
Release Yoke (Clutch Pedal in UP Position) Clutch Brake Clutch Cover Finger Wear Pad ( With NO free Play)
Service Procedure
Transmission
27
Mesh Input Shaft and Disc(s) by Rotating Output Shaft
29
Adjust the Linkage
STROKE PEDAL 5 TIMES
30
Fully Depress Clutch Pedal 5 Times Solo Heavy Duty 15.5" Clutch Installation
24
Service Procedure
Eaton Fuller Solo Medium Duty 1401 Clutches

Eaton Fuller Solo XL and Maintenance-Free Clutches require a specially designed release yoke (97-509-10-1X). The Roller Yoke can only be used with Solo XL and Maintenance-Free type clutches. Eaton recommends that any time a new Solo Maintenance-Free Clutch or a Solo Extended Lube Clutch is installed that a new roller yoke also be installed. Eaton Fuller service part numbers 109410-xY 109507-xxY and 109508xxY include the roller yoke. Non XL, Maintanence-Free and Eaton Fuller Medium Duty Solo uses a standard yoke 105C137 or equivalent. Note the position of the wear indicating tab on the clutch. If the tab is near the "REPLACE" position, the clutch should be replaced. When fully assembled, the 14 Clutch weighs approximately 70 pounds. A hydraulic clutch jack is recommended.
Required Tools
Essential Steps
If a Solo Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (3/8" x 16 UNC x 1- 1/4"). Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening.
Specifications
ENGINE
Clutch
Transmission
25
Clutch Assembly Driven Disc Driven Disc
Service Procedure
Flywheel Bore
Service Procedure
26
Service Procedure
Solo Medium Duty 1401 Clutch - Remove

Procedure1. Remove the transmission, supporting its weight to prevent damage to the bearing and discs. Note: If a Solo Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (3/8" x 16 UNC x 1- 1/4"). 2. Locate four (4) 3/8" x 16 x 1 1/4" UNC, hex head machine screws. Install them in the 4 cover holes, turning them one complete turn after they contact the cover. Remove the clutch from the flywheel. Note: Mark the proper position of the discs and intermediate plate adapter ring (for reinstallation).
3.
27
Service Procedure
1
2
Located 4 Hex Head Machine Screws
(4) 3/8" x 16 x 1-1/4" UNC
Service Procedure
Solo Medium Duty 1401 Clutch Removal
28
Service Procedure
Solo Medium Duty 1401 Clutch - Install

Procedure1. Remove the old pilot bearing and wipe all surfaces that will contact the gauging. Secure the dial indicator to the flywheel housing with the gauge finger near the outer edge of the flywheel. 8. 3. Use a soapstone to mark the high and low spots as you rotate the flywheel one (1) revolution. The difference between these two spots should be .008" (0.2 mm) or less. With the dial indicator still secured to the flywheel housing, continue the inspection process by moving the gauge finger so it contacts the pilot bearing bore surface. Rotate the flywheel one (1) revolution. The maximum allowed run out must be .005" (0.13 mm). Secure the dial indicator to the crankshaft with the gauge finger against the flywheel housing pilot area. 7. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Secure the dial indicator to the flywheels outer diameter and move the gauge finger until it contacts the face of the flywheel housing. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Note: If the above four (4) limits are exceeded, the problem must be corrected. Misalignment will cause damper failure and wear to drivetrain components. 10. Install a new pilot bearing. Eaton strongly recommends the use of a premium grade pilot bearing. The bearing must have a press fit. Note: Tap on the outer race only. Tapping the inner race could cause damage to the pilot bearing.
2.
9.
4.
5.
6.
29
Service Procedure
1
2
3
4
6
Secure the Dial Indicator to Crankshaft
Service Procedure
5
7
8
9
10
30
Solo Medium Duty 1401 Clutch Installation
Service Procedure
Solo Medium Duty 1401 Clutch - Install, Cont

11. Check the following items for wear and replace any worn components: a. Cross-shafts and bushings 13. Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening and not interfere with flywheel mounting bolts.
Note: Excessive wear at these points can cause a side loading condition onto the sleeve bushing of the newly installed Solo Clutch. Consequently, this condition can cause the bushing to walk-out of the sleeve. Also, inspect the remaining pivot points of the linkage for excessive wear. b. c. Release yoke fingers Transmission bearing retainer cap
Note: This applies only if a clutch brake is used (non-synchronized transmission). A worn/rough bearing retainer cap may cause the newly installed clutch brake to wear prematurely. Also, excess wear at either the transmission bearing retainer cap (arrow C) and/or the release yoke fingers (arrow B) may prevent the linkage from obtaining a sufficient amount of clutch brake squeeze (Recommended range is 1/2" 1" (13 24 mm). Refer to arrow G concerning the nominal distance between the input shafts end and the bearing retainer cap. d. Splines on the input shaft
Note: Inspect the mating surfaces of both the transmission bell housing and the flywheel housing. Any appreciable wear on either housing will cause misalignment. Most wear will occur between the 3 and 8 oclock positions. Replace housings if worn. 12. Install a new Eaton Fuller clutch brake at this time. Note: This applies only if a clutch brake is used (non-synchronized transmission).
31
Service Procedure
Service Procedure
11E Check Smooth Area of Input Shaft for Wear/Roughness Solo Medium Duty 1401 Clutch Installation
32
Service Procedure

14. Insert two (2) 3/8" x 16 thread x 3" (76 mm) long guide studs into the two upper mounting holes of the flywheel. Note: Refer to the label on the Solos shipping box to verify that the clutchs maximum torque rating is greater than the engines peak torque rating. Premature-failure (a slipping clutch) will occur if the engines toque rating exceeds that of the clutch. 15. Install the disc by inserting the aligning tool through the disc splines and then into the pilot bearing. Note: Make sure the side marked Pressure Plate Side faces the pressure plate. 16. With the aligning tool still in place, carefully slide the clutch assembly over the aligning tool and the two (2) guide studs. 17. Start six (6) 3/8" Grade 5 or better mounting bolts and hand tighten. Remove the two (2) guide studs and replace with the remaining mounting bolts. Using a torque wrench, progressively tighten the eight (8) mounting bolts to 30 35 lbs. ft. (40 47 Nm) of torque using the following criss-cross pattern. Starting at the lower left. Note: Failure to tighten these bolts in this manner can: Prevent the clutch cover from centering into the pilot area of the flywheel. Cause permanent damage to the clutch cover (i.e. become cracked or broken). Cause the clutch assembly to be out-of balance with the flywheel.
18. Remove the four (4) yellow colored shipping bolts in a criss-cross pattern. Note: Save these four (4) bolts for future use in case you need to remove, then reinstall the Solo Clutch. 19. Remove the aligning tool. 20. Shift the transmission into gear and verify that a new Eaton Fuller Clutch Brake has been installed if so equipped.
33
Service Procedure
14
15
Install the Disc Using the Aligning Tool
16
Slide Clutch Assembly Over Aligning Tool and Guide Studs
Guide Studs
Aligning Tool
2 7
Service Procedure
4 8 1 5
17
Start 8 Mounting Bolts Replacing the 2 Guide Studs
18
SHIFT INTO GEAR

19
Remove the Aligning Tool
20
34
Service Procedure

21. Position the transmission so that it is both square to and aligned with the engine. 22. While moving the transmission forward, rotate the output shaft of the transmission until the splines of both the input shaft and the disc(s) mesh with each other. While performing this task, you must also ensure that the yoke fingers remain in the up position until they can be rotated over the release bearing housing into their final position. CAUTION: Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position. Doing so may release the clutch and overstroke the release bearing. The Solo will incorrectly set the release bearing position too close to the transmission and cause the wear indicating tab to move to 1/31/2 the distance towards the REPLACE position. CAUTION: Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and make any necessary changes. CAUTION: If the input shaft will not slide into the discs, they may need to be repositioned. If the clutch is to be unbolted from the flywheel, re-install the shipping bolts and tighten one turn past contact with the clutch. Now the installation shaft can be installed to reposition the discs and the clutch bolts re-torqued. Remove the shipping bolts to clamp the discs. CAUTION: Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch will not release. 23. Install the transmission mounting bolts and torque to the proper specification. 24. Position a pipe (or similar tool) over the crossshaft release lever and rotate it until the release bearing comes to a complete stop. Repeating this procedure a total of five (5) times will ensure that the Solo adjusts fully to its new environment. 25. If the truck has a mechanical linkage system, reconnect the linkage and adjust it until you obtain a yoke gap range of .062 .125" (2 3 mm). If the truck has a hydraulic linkage system, consult the truck manufacturers service manual. 26. If the truck is equipped with a clutch brake, verify that the clutch brake is being squeezed approximately 1/2" (13 mm) from the bottom of the clutch pedal stroke. If you cannot obtain any clutch brake squeeze, you will need to increase the overall clutch pedal travel, (use the adjustable pedal stop) and then readjust the linkage to again obtain a free pedal range of .062 .125" (2 3 mm). 27. Grease the release bearing until grease purges from the rear of the release bearing (toward transmission) and flows onto the transmission shaft.
35
Service Procedure
21
Align Transmission with Engine
Service Procedure
22
Mesh Splines of Input Shaft and Disc(s) Using Output Shaft
27
Grease the Release Bearing
36
Service Procedure
Eaton Fuller Solo Medium Duty 1402 Clutches

Eaton Fuller Solo XL and Maintenance-Free Clutches require a specially designed release yoke (97-509-10-1X). The Roller Yoke can only be used with Solo XL and Maintenance-Free type clutches. Eaton recommends that any time a new Solo Maintenance-Free Clutch or a Solo Extended Lube Clutch is installed that a new roller yoke also be installed. Eaton Fuller service part numbers 109410-xY 109507-xxY and 109508xxY include the roller yoke. Non XL, Maintenance-Free and Eaton Fuller Medium Duty Solo uses a standard yoke 105C137 or equivalent. Note the position of the wear indicating tab on the clutch. If the tab is near the "REPLACE" position, the clutch should be replaced. CAUTION: When fully assembled, the 14 Clutch weighs approximately 100 pounds. A hydraulic clutch jack is recommended.
Required Tools
Essential Steps
If a Solo Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (3/8" x 16 UNC x 1- 1/4"). Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening.
Specifications
ENGINE
Clutch
Transmission
37
Service Procedure
Flywheel Bore
Service Procedure
38
Service Procedure
Solo Medium Duty 1402 Clutch - Remove

Procedure1. Remove the transmission, supporting its weight to prevent damage to the bearing and discs. Note: If a Solo Clutch is to be removed and reinstalled on the flywheel, four (4) shipping bolts must be installed prior to unbolting the clutch (3/8" x 16 UNC x 1- 1/4"). 2. Locate four (4) 3/8" x 16 x 1 1/4" UNC, hex head machine screws. Install them in the 4 cover holes, turning them one complete turn after they contact the cover. Remove the clutch from the flywheel. Note: Mark the proper position of the discs and intermediate plate adapter ring (for reinstallation).
3.
39
Service Procedure
1
2
Locate Four Hex Head Machine Screws
(4) 3/8" x 16 x 1-1/4" UNC
Service Procedure
Solo Medium Duty 1402 Clutch Removal
40
Service Procedure
Solo Medium Duty 1402 Clutch - Install

Procedure1. Remove the old pilot bearing and wipe all surfaces that will contact the gauging. Secure the dial indicator to the flywheel housing with the gauge finger near the outer edge of the flywheel. 8. 3. Use a soapstone to mark the high and low spots as you rotate the flywheel one (1) revolution. The difference between these two spots should be .008" (0.2 mm) or less. With the dial indicator still secured to the flywheel housing, continue the inspection process by moving the gauge finger so it contacts the pilot bearing bore surface. Rotate the flywheel one (1) revolution. The maximum allowed run out must be .005" (0.13 mm). Secure the dial indicator to the crankshaft with the gauge finger against the flywheel housing pilot area. 7. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Secure the dial indicator to the flywheels outer diameter and move the gauge finger until it contacts the face of the flywheel housing. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. CAUTION: If the above four (4) limits are exceeded, the problem must be corrected. Misalignment will cause damper failure and wear to drivetrain components. 10. Install a new pilot bearing. Eaton strongly recommends the use of a premium grade pilot bearing. The bearing must have a press fit. Note: Tap on the outer race only. Tapping the inner race could cause damage to the pilot bearing.
2.
9.
4.
5.
6.
41
Service Procedure
1
2
3
4
6
5
7
8
9
10
42
Service Procedure

11. Check the following items for wear and replace any worn components: a. Cross-shafts and bushings 12. Install a new Eaton Fuller Clutch Brake at this time. Note: This applies only if a clutch brake is used (non-synchronized transmission). 13. Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening and not interfere with flywheel mounting bolts.
Note: Excessive wear at these points can cause a side loading condition onto the sleeve bushing of the newly installed Solo Clutch. Consequently, this condition can cause the bushing to walk-out of the sleeve. Also, inspect the remaining pivot points of the linkage for excessive wear. b. c. Release yoke fingers Transmission bearing retainer cap
Note: Inspect the mating surfaces of both the transmission bell housing and the flywheel housing. Any appreciable wear on either housing will cause misalignment. Most wear will occur between the 3 and 8 oclock positions. Replace housings if worn.
43
Service Procedure
Service Procedure
11E Check Smooth Area of Input Shaft for Wear/Roughness Solo Medium Duty 1402 Clutch Installation
44
Service Procedure

14. Insert two (2) 3/8" x 16 thread x 3" (76 mm) long guide studs into the two upper mounting holes of the flywheel. Note: Refer to the label on the Solos shipping box to verify that the clutchs maximum torque rating is greater than the engines peak torque rating. Premature-failure (a slipping clutch) will occur if the engines toque rating exceeds that of the clutch. 15. Install the front disc by inserting the aligning tool through the disc splines and then into the pilot bearing. Note: Make sure the side marked Flywheel Side faces the flywheel. 16. Install the intermediate plate assembly over the two (2) guide studs and slide it forward until it touches the flywheel. Note: Make sure the side marked Pressure Plate Side is facing the pressure plate (the drive straps must face the pressure plate). 17. Remove the aligning tool and install it through the splines of the rear disc, and insert the aligning tool through the front disc and also the pilot bearing. Note: Make sure the side of the disc marked Pressure Plate Side is facing the pressure plate. As you complete this step, ensure that the ceramic buttons align with each other as closely as possible. Doing so will aid the function of the positive separator pins (roll pins). 18. With the aligning tool still in place, slide the cover assembly over both the aligning tool and the two (2) guide studs until it rests against the intermediate plate assembly. 19. Start six (6) 3/8" x 2.44" (10 x 62 mm) Grade 5 or better mounting bolts and hand tighten. Remove the two (2) guide studs and replace with the remaining mounting bolts. Using a torque wrench, progressively tighten the eight (8) mounting bolts to 30 35 ft. lbs. (40 47 Nm) of torque using the following criss-cross pattern. Note: Failure to tighten these bolts in this manner can: Prevent the clutch cover from centering into the pilot area of the flywheel. Cause permanent damage to the clutch cover (i.e. become cracked or broken). Cause the clutch assembly to be out-of balance with the flywheel.
45
Service Procedure
14
15
Guide Studs
Aligning Tool
Buttons
Service Procedure
16
17
2 7
4 8 1 5
18
Slide Cover Assembly Over Aligning Tool and Guide Studs Solo Medium Duty 1402 Clutch Installation
19
Start 8 Mounting Bolts Replacing the 2 Guide Studs
46
Service Procedure

20. Remove the four (4) yellow colored shipping bolts in a criss-cross pattern. Note: Save these four (4) bolts for future use in case you need to remove, then reinstall the Solo Clutch. 21. Remove the aligning tool. 22. Using a 1/4" (6 mm) diameter flat nose punch, lightly tap each of the four (4) Positive Separator Pins toward the flywheel. Performing this step will verify that all four (4) pins are flush against the flywheel. CAUTION: Failure to perform this step properly may cause the clutch to drag (clutch does not release). Excessive force can damage the pins and cause a release problem. Note: The four (4) pins can also be set through the inspection opening of the transmission bell housing if they were not to set prior to transmission installation. 23. Shift the transmission into gear and verify that a new Eaton Fuller Clutch Brake has been installed if so equipped. 24. Position the transmission so that it is both square to and aligned with the engine. CAUTION: Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position. Doing so may release the clutch and overstroke the release bearing. The Solo will incorrectly set the release bearing position too close to the transmission and cause the wear indicating tab to move to 1/31/2 the distance towards the REPLACE position. CAUTION: Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and make any necessary changes. CAUTION: If the input shaft will not slide into the discs, they may need to be repositioned. If the clutch is to be unbolted from the flywheel, re-install the shipping bolts and tighten one turn past contact with the clutch. Now the installation shaft can be installed to reposition the discs and the clutch bolts re-torqued. Remove the shipping bolts to clamp the discs. CAUTION: Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch will not release. 25. While moving the transmission forward, rotate the output shaft of the transmission until the splines of both the input shaft and the disc(s) mesh with each other. While performing this task, you must also ensure that the yoke fingers remain in the up position until they can be rotated over the release bearing housing into their final position.
47
Service Procedure
20
21
Remove the Aligning Tool
ACCESS HOLE
ROLL PIN
CLUTCH COVER
Service Procedure
SHIFT INTO GEAR

23 22
Tap Separator Pins Until They are Flush Aginst Flywheel Shift Transmission into Gear
24
Align Transmission with Engine Solo Medium Duty 1402 Clutch Installation
25
Mesh Splines of Input Shaft and Disc(s) Using Output Shaft
48
Service Procedure

26. Install the transmission mounting bolts and torque to the proper specification. 27. Position a pipe (or similar tool) over the cross shaft release lever and rotate it until the release bearing comes to a complete stop. Repeating this procedure a total of five (5) times will ensure that the Solo adjusts fully to its new environment. 28. If the truck has a mechanical linkage system, reconnect the linkage and adjust it until you obtain a yoke gap range of .062 .125" (2 3 mm). If the truck has a hydraulic linkage system, consult the truck manufacturers service manual. 29. If the truck is equipped with a clutch brake, verify that the clutch brake is being squeezed approximately 1/2" (13 mm) from the bottom of the clutch pedal stroke. If you cannot obtain any clutch brake squeeze, you will need to increase the overall clutch pedal travel, (use the adjustable pedal stop) and then readjust the linkage to again obtain a free pedal range of .062 .125" (2 3 mm). 30. Grease the release bearing until grease purges from the rear of the release bearing (toward transmission) and flows onto the transmission shaft.
49
Service Procedure
28
Adjust Linkage Appropriately
RELEASE YOKE CROSS SHAFT
FINGER CLUTCH A
TRANSMISSION
29
Adjust Free Pedal
Free Pedal Range .062" - .125" (2mm - 3mm)
Service Procedure
1/2" - 1" (13 - 25mm)
30
Grease the Release Bearing
50
Service Procedure
Eaton Fuller Easy Pedal 15.5" Clutches

CAUTION: When fully assembled, the 14" clutch weighs approximately 150 pounds (68 kg). A hydraulic clutch jack is recommended.
Required Tools
Essential Steps
Follow the instructions stamped on the discs to insure correct orientation. Verify diameter of the flywheel bore (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening. 10-spring driven discs require 8.56" (219 mm) dia. (minimum) 6-spring (V.C.T.) driven discs require 9.75" (248 mm) dia. (minimum) 7-spring driven discs require 9.75" (248 mm) dia. (minimum) 9-spring driven discs require 9.75" (248 mm dia. (minimum) (Mack Engines Only) 8-spring driven discs require 7.25" (184 mm) dia. (minimum)
Specifications
ENGINE
Clutch
Transmission
51
Service Procedure
Service Procedure
EP
R ES
S BOLT
Clutch Assembly
TU
RN
Flywheel bore
52
Service Procedure
Easy Pedal 15.5" Clutch - Remove

Procedure1. Remove the transmission, supporting its weight to prevent damage to the bearing and discs. Install two wooden spacers 1/2 - 5/8 thick between release bearing and cover assembly. Remove the clutch from the flywheel. Note: Mark the proper position of the discs and intermediate plate adapter ring (for reinstallation).
2.
3.
53
Service Procedure
1
Service Procedure
Easy Pedal 15.5 Clutch Removal
54
Service Procedure
Easy Pedal 15.5" Clutch - Install

Procedure1. Remove the old pilot bearing and wipe all surfaces that will contact the gauging. Secure the dial indicator to the flywheel housing with the gauge finger near the outer edge of the flywheel. 8. 3. Use a soapstone to mark the high and low spots as you rotate the flywheel one (1) revolution. The difference between these two spots should be .008" (0.2 mm) or less. With the dial indicator still secured to the flywheel housing, continue the inspection process by moving the gauge finger so it contacts the pilot bearing bore surface. Rotate the flywheel one (1) revolution. The maximum allowed run out must be .005" (0.13 mm). Secure the dial indicator to the crankshaft with the gauge finger against the flywheel housing pilot area. 7. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Secure the dial indicator to the flywheels outer diameter and move the gauge finger until it contacts the face of the flywheel housing. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. CAUTION: If the above four (4) limits are exceeded, the problem must be corrected. Misalignment will cause damper failure and wear to drivetrain components. 10. Install a new pilot bearing. Eaton strongly recommends the use of a premium grade pilot bearing. The bearing must have a press fit. Note: Tap on the outer race only. Tapping the inner race could cause damage to the pilot bearing.
2.
9.
4.
5.
6.
55
Service Procedure
1
2
3
4
6
5
7
8
9
10
56
Easy Pedal 15.5" Clutch Installation
Service Procedure
Easy Pedal 15.5" Clutch - Install, Cont

11. Check the following items for wear and replace any worn components: a. Cross-shafts and bushings 12. Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening. Note: Excessive wear at these points can cause a side loading condition. Also, inspect the remaining pivot points of the linkage for excessive wear. b. c. Release yoke fingers Transmission bearing retainer cap 10-spring driven discs require 8.56" (219 mm) dia. (minimum) 6-spring (V.C.T.) driven discs require 9.75" (248 mm) dia. (minimum) 7-spring driven discs require 9.75" (248 mm) dia. (minimum) 8-spring driven discs require 7.25" (184 mm) dia. (minimum) 9-spring driven discs require 9.75" (248 mm)
Note: A worn/rough bearing retainer cap may cause the newly installed clutch brake to wear prematurely. Also, excess wear at either the transmission bearing retainer cap (arrow C) and/or the release yoke fingers (arrow B) may prevent the linkage from obtaining a sufficient amount of clutch brake squeeze (Recommended range is 1/2" 1" (13 24 mm). Refer to arrow G concerning the nominal distance between the input shafts end and the bearing retainer cap. d. Splines on the input shaft
Note: Any wear on the splines will prevent the newly installed driven discs from sliding freely, thus causing poor release (clutch drag). Select a disc out of the new installation and slide it full length on the transmission splines. This will detect a twisted input shaft. Replace input shaft if disc does not freely slide. e. f. Smooth area of input shaft Mating surfaces
57
Service Procedure
Service Procedure
11E Check Smooth Area of Input Shaft for Wear/Roughness Easy Pedal 15.5" Clutch Installation
58
Service Procedure

13. Insert two (2) 7/6" x I4 UNC x 5" (127mm) long guide studs into the two upper mounting holes of the flywheel. 14. Insert the aligning tool through the release bearing sleeve of the new clutch. 15. Put the rear driven disc on the aligning tool, following the directions stamped on the disc. If discs are incorrectly installed, the clutch will not release and damage to the disc may occur. Note: Follow the instructions stamped on the discs to insure correct orientation. 6 Spring/V.C.T.: both discs are identical and can be installed in any direction. 7 Spring: Both discs are identical but must be installed following the instructions Intermediate Plate Side. 8, 9 and 10 Spring: Discs are marked Pressure Plate Side and Flywheel Side. 16. Place the intermediate plate in the clutch cover and align the driving lugs of the plate with the slots provided. Note: Positive separator (roll) pins should be flush on clutch side and protruding on flywheel side. 17. Install the front disc on the aligning tool with the side stamped Intermediate Plate Side facing the intermediate plate. Note: The relative position of the buttons on the front and rear driven discs is not important. Note: Make sure that the adjustment mechanism will be aligned with the opening in the bell housing of the transmission. 18. Position the clutch over the guide studs and slide it forward until contact is made with the flywheel surface. CAUTION: A 15.5" clutch assembly weighs about 150 pounds. A hoist may be required to lift it into place.
59
Service Procedure
13
14
Insert the Aligning Tool Through Release Bearing Sleeve
Guide Studs
Service Procedure
15
16
17
Place Second Disc on Aligning Tool Properly Orientated Easy Pedal 15.5" Clutch Installation
18
Place Clutch Over 2 Guide Studs and Slide Forward
60
Service Procedure

19. Start six (6) 7/16" x 14 UNC x 2- 1/4" (57 mm) Grade 5 or better mounting bolts with lock washers and tighten them finger-tight. Remove the two (2) guide studs and replace them with the two (2) remaining mounting bolts/ lock washers. 20. Starting with the lower left-hand bolt, progressively tighten the eight (8) mounting bolts in a criss-cross pattern until you achieve final torque of 4050 ft. lbs. (54-68 Nm). As the bolts are tightened, the wooden spacers could fall out. If they do not fall free, remove them. You may have to lightly tap on the aligning tool with a mallet to remove them. Note: Failure to tighten these bolts in this manner can: Prevent the clutch cover from centering into the pilot area of the flywheel. Cause permanent damage to the clutch cover (i.e. become cracked or broken). Cause the clutch assembly to be out-of balance with the flywheel. 23. Shift the transmission into gear. Note: If a clutch brake is used, be sure to install it on the input shaft of the transmission at this time. 24. Position the transmission so that it is both square to and aligned with the engine. 22. Using a 1/4" (6 mm) diameter flat nose punch, lightly tap each of the four (4) Positive Separator Pins toward the flywheel. Performing this step will verify that all four (4) pins are flush against the flywheel. CAUTION: Failure to perform this step properly may cause the clutch to drag (clutch does not release). Excessive force can damage the pins and cause a release problem. Note: The four (4) pins can also be set through the inspection opening of the transmission bell housing if they were not to set prior to transmission installation.
21. Remove the aligning tool. Note: Bearing position should be approximately .375" .625" (9.52 15.87 mm) from the clutch cover.
61
Service Procedure
19
Start 6 Mounting Bolts and Replace the 2 Guide Bolts
6
20
2
3 1 5
Service Procedure
21
22
Tap the Separator Pins Towards the Flywheel
SHIFT INTO GEAR
23
Shift Transmission into Gear Easy Pedal 15.5" Clutch Installation
24
Align Transmission With Engine
62
Service Procedure

25. While moving the transmission forward, rotate the output shaft of the transmission until the splines of both the input shaft and the disc(s) mesh with each other. While performing this task, you must also ensure that the yoke fingers remain in the up position until they can be rotated over the release bearing housing into their final position. CAUTION: Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position. CAUTION: Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and make any necessary changes. CAUTION: If the input shaft will not slide into the discs, they may need to be repositioned. CAUTION: Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch will not release. 26. Install the transmission mounting bolts and torque to the proper specification. 27. Set Bearing Position. Set the distance between the bearing and clutch brake .500" .562" (13 14 mm). Note: This dimension is critical, do not set less than .500" (13mm) or more than the .562" (14 mm) under any circumstances. a. b. Use the internal adjustment on the clutch to move the bearing. Put slight tension on linkage to insure that bearing is stretched and no movement toward engine is noticed. Measure with an inside caliper to prevent moving the bearing toward engine. down to verify that the linkage moves the release bearing enough to clamp the feeler gauge. b. The linkage should be adjusted to allow clamp up of the feeler gauge with the pedal down (1/2" [13 mm] from floor) and to release the feeler gauge when the pedal is not over 1" from the floor.
29. Check free pedal. (Do not internally adjust the clutch to move the release bearing closer to the clutch brake. This will reduce the stroke to the clutch and it will not release.) a. The release fork fingers should be approximately .125" (3.2 mm) from the release bearing wear pads. (This will create 1" to 3" of free pedal in the cab.) This will be the normal free pedal for this truck. Clutch adjustment should be performed when the free pedal is 1/2 of normal. (Example: If free pedal is 2" after correct adjustment, the clutch should be adjusted when free pedal reaches 1".)
b.
c.
Note: The Bearing (and internal components) must move .500" (13 mm) minimum or the clutch wont release. Eliminate lost motion before checking. 28. Adjust Clutch Brake and truck linkage. (Do not change the bearing position by the internal clutch adjustment.) a. Insert a .010" (.25 mm) feeler gauge between the release bearing and clutch brake. Push the pedal
63
Service Procedure
25
.500" (13mm) Adjust Internally
27
Set Bearing Position
Clockwise - moves the bearing toward the transmission (decrease gap) Counterclockwise - moves the bearing toward the engine (increases gap) Kwik Adjust - push in and turn Easy pedal (2 1/3 rotations = 1/8") Easy pedal 2000 (1 rotation = 1/8") Fork Style - remove fork and move lugs
.500" .5625" (13mm 14mm)
Service Procedure
1/2" - 1" (13 - 25mm)
.010 Feeler Guage
28
Adjust Clutch Brake
Measure & record in-cab free pedal
29
Check Free Pedal
Easy Pedal 15.5" Clutch Installation
64
Service Procedure
Eaton Fuller Easy Pedal Plus 14" Clutches

Do not file the drive pin slots on the intermediate plate to obtain correct clearances. Doing so will cause an unequal load on the pins. This is a frequent cause of poor release or the clutch not releasing at all. It can also result in broken drive pins. CAUTION: When fully assembled, the 14" clutch weighs approximately 150 pounds. A hydraulic clutch jack is recommended.
Required Tools
Essential Steps
Make sure the side stamped Flywheel Side faces the engine and the side stamped Pressure Plate Side faces the transmission. CAUTION: Failure to install anti-rattle springs wil result in broken drive pins and release problems.
Specifications
ENGINE
Clutch
Transmission
65
Service Procedure
Service Procedure
EP
R ES
S BOLT
Clutch Assembly
TU
RN
Flywheel bore
66
Service Procedure
Easy Pedal 14" Clutch - Remove

2.
3.
67
Service Procedure
1
Service Procedure
Easy Pedal 14 Clutch Removal
68
Service Procedure
Easy Pedal 14" Clutch - Install

Procedure1. Remove the old pilot bearing and wipe all surfaces that will contact the gauging. Secure the dial indicator to the flywheel housing with the gauge finger near the outer edge of the flywheel. 8. 3. Use a soapstone to mark the high and low spots as you rotate the flywheel one (1) revolution. The difference between these two spots should be .007 (0.2 mm) or less. With the dial indicator still secured to the flywheel housing, continue the inspection process by moving the gauge finger so it contacts the pilot bearing bore surface. Rotate the flywheel one (1) revolution. The maximum allowed run out must be .005" (0.13 mm). Secure the dial indicator to the crankshaft with the gauge finger against the flywheel housing pilot area. 7. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Secure the dial indicator to the flywheels outer diameter and move the gauge finger until it contacts the face of the flywheel housing. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Note: If the above four (4) limits are exceeded, the problem must be corrected. Misalignment will cause damper failure and wear to drivetrain components. 10. Install a new pilot bearing. Eaton strongly recommends the use of a premium grade pilot bearing. The bearing must have a press fit. Note: Tap on the outer race only. Tapping the inner race could cause damage to the pilot bearing.
2.
9.
4.
5.
6.
69
Service Procedure
1
2
3
4
6
5
7
8
9
10
70
Easy Pedal 14 Clutch Installation
Service Procedure
Easy Pedal 14" Clutch - Install, Cont

11. Check the following items for wear and replace any worn components: a. Cross-shafts and bushings 12. Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening. 13. Install six (6) new drive pins in the previously unused holes in the flywheel using a brass hammer. Space them out equally. Make sure that the shanks of the pins are a press fit in the flywheel rim.
Note: Excessive wear at these points can cause a side loading condition. Also, inspect the remaining pivot points of the linkage for excessive wear. b. c. Release yoke fingers Transmission bearing retainer cap
Note: A worn/rough bearing retainer cap may cause the newly installed clutch brake to wear prematurely. Also, excess wear at either the transmission bearing retainer cap (arrow C) and/or the release yoke fingers (arrow B) may prevent the linkage from obtaining a sufficient amount of clutch brake squeeze (Recommended range is 1/2" 1" (13 24 mm). Refer to arrow G concerning the nominal distance between the input shafts end and the bearing retainer cap. d. Splines on the input shaft
71
Service Procedure
Service Procedure
11E Check Smooth Area of Input Shaft for Wear/Roughness Easy Pedal 14" Clutch Installation
72
Service Procedure

14. Place front disc into flywheel with the side marked Flywheel Side toward the flywheel/engine. Note: Make sure the side marked Flywheel Side faces the flywheel/engine. 15. Position the intermediate plate on the six (6) drive pins (use new slots if reinstallation or remanufactured assembly). 16. Turn the intermediate plate to right. Measure clearance on right side of the six (6) drive pins. 17. Use a .006" (.15 mm) feeler gauge to check the clearance between the drive pin and the drive slot. Check the same side of each pin. Note: The minimum clearance between the drive pins and the drive slots is .006" (.15 mm). If the proper clearance is not obtained, the clutch will not release. Note: Do not set pins with square or alignment block (they should be used for approximate initial setting). 18. If the alignment and clearance is correct, lock each of the six (6) pins in place with two (2) new, 3/8" x 3/8" set screws. 19. Recheck the clearances. This check is necessary to ensure that the clutch will release properly when installed. Note: Do not file the drive pin slots on the intermediate plate to obtain correct clearances. Doing so will cause an unequal load on the pins. This is a frequent cause of poor release or the clutch not releasing at all. It can also result in broken drive pins. Standard Duty - clutches use thin intermediate plate approximately .580" .630" (15 16 mm) and discs approximately .450" (11mm). Super Duty - Clutches use a thicker intermediate plate approximately .750" .810" (19 21 mm) and thin discs approximately .360" (9 mm). IMPORTANT: If you are installing a Super Duty Clutch with a thick intermediate plate, install three (3) anti-rattle springs. Space them equally between the drive pins with the rounded sections toward the flywheel face marked arrow toward the engine. CAUTION: Wear heavy gloves when installing anti-rattle springs. Note: Failure to install anti-rattle springs will result in broken drive pins and release problems. 20. Insert the aligning tool through the hub of the rear disc with the side stamped Pressure Plate Side facing the transmission and install it after the intermediate plate. Note: Make sure the side stamped Flywheel Side faces the engine and the side stamped Pressure Plate Side faces the transmission. 21. Re-insert the aligning tool through the hub of the front driven disc and into the pilot bearing. Note: The relative position of the buttons on the front and rear driven discs is not important. 22. Insert two (2) 3/8" x 2-1/2 long guide studs into the two upper mounting holes of the flywheel. 23. Position the clutch over the two (2) guide studs and slide it forward until contact is made with the flywheel surface. CAUTION: Make sure that the adjustment mechanism will be aligned with the opening in the bell housing of the transmission. When fully assembled, the clutch weighs approximately 150 pounds (68 kg). A hydraulic clutch jack is recommended.
73
Service Procedure
14
Place Front Disc into Flywheel
17
Check Clearance
Service Procedure
19
Wear Heavy Glove When Installing AntiRalltle Springs
20
Insert Aligning Tool Through Rear Disc
22
23
Position the Clutch Over Guide Studs and Slide Forward
74
Easy Pedal 14 Clutch Installation
Service Procedure

24. Start six (6) 3/8" x 1- 1/4" Grade 5 or better mounting bolts with lock washers and tighten them finger-tight. Remove the two (2) guide studs and replace them with the two (2) remaining mounting bolts/lock washers. 25. Starting with the lower left-hand bolt, progressively tighten the eight (8) mounting bolts in a criss-cross pattern until you achieve a final torque of 25 35 ft. lbs (34 47 Nm). As the bolts are tightened, the wooden spacers could fall out. If they do not fall free, be sure to remove them. You may have to lightly tap the aligning tool with a mallet to remove them. Note: Failure to tighten these bolts in this manner can: Prevent the clutch cover from centering into the pilot area of the flywheel. Cause permanent damage to the clutch cover (i.e. become cracked or broken). Cause the clutch assembly to be out-of balance with the flywheel. CAUTION: Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and make any necessary changes. CAUTION: If the input shaft will not slide into the discs, they may need to be repositioned. Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch will not release. 28. Position the transmission so that it is both square to and aligned with the engine. 29. While moving the transmission forward, rotate the output shaft of the transmission until the splines of both the input shaft and the disc(s) mesh with each other. While performing this task, you must also ensure that the yoke fingers remain in the up position until they can be rotated over the release bearing housing into their final position. CAUTION: Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position.
Note: Bearing position should be approximately .375" .625" (9.5 15.9 mm) from the clutch cover. 26. Remove the aligning tool. 27. Shift the transmission into gear. Note: If a clutch brake is used, be sure to install it on the input shaft of the transmission at this time.
75
Service Procedure
24
Start 6 Mounting Bolts and Replace the 2 Giude Bolts
25
7 3 8
Service Procedure
SHIFT INTO GEAR

27 26
Remove the Aligning Tool Shift the Transmission into Gear
28
Align the Tranmission with the Engine Easy Pedal 14" Clutch Installation
29
76
Service Procedure

30. Install the transmission mounting bolts and torque to the proper specification. 31. Set Bearing Position. Set the distance between the bearing and clutch brake .500" .562" (13 14 mm). Note: This dimension is critical, do not set less than .500" (13 mm) or more than the .562" (14 mm) under any circumstances. a. b. Use the internal adjustment on the clutch to move the bearing. Put slight tension on linkage to insure that bearing is stretched and no movement toward engine is noticed. Measure with an inside caliper to prevent moving the bearing toward engine. 32. Adjust clutch brake and truck linkage. (Do not change the bearing position by the internal clutch adjustment.) a. Insert a .010" (.25 mm) feeler gauge between the release bearing and clutch brake. Push the pedal down to verify that the linkage moves the release bearing enough to clamp the feeler gauge. The linkage should be adjusted to allow clamp up of the feeler gauge with the pedal down (1/2" [13 mm] from floor) and to release the feeler gauge when the pedal is not over 1" from the floor.
b.
33. Check free pedal. (Do not internally adjust the clutch to move the release bearing closer to the clutch brake. This will reduce the stroke to the clutch and it will not release.) a. The release fork fingers should be approximately .125" (3.2 mm) from the release bearing wear pads. (This will create 1" to 3" of free pedal in the cab.) This will be the normal free pedal for this truck. Clutch adjustment should be performed when the free pedal is 1/2 of normal. (Example: If free pedal is 2" after correct adjustment, the clutch should be adjusted when free pedal reaches 1".).
c.
Note: The Bearing (and internal components) must move .500" (13 mm) minimum or the clutch wont release. Eliminate lost motion before checking.
b.
77
Service Procedure
.500" (13mm) Adjust Internally Clockwise - moves the bearing toward the transmission (decrease gap) Counterclockwise - moves the bearing toward the engine (increases gap) Kwik Adjust - push in and turn Easy pedal (2 1/3 rotations = 1/8") Easy pedal 2000 (1 rotation = 1/8") Fork Style - remove fork and move lugs
.500" .5625" (13mm 14mm)
1/2" - 1" (13 - 25mm)
31
.010 Feeler Guage
32
Adjust Clutch Brake
Service Procedure
33
Check Free Pedal
Easy Pedal 14" Clutch Installation
78
Service Procedure
Eaton Fuller Stamped Angle Spring 1401 Clutches

When fully assembled, the 14" clutch weighs approximately 70 pounds (32 kg). A hydraulic clutch jack is recommended.
Required Tools
Specifications
Essential Steps
None
ENGINE
Clutch
Transmission
79
Service Procedure
Service Procedure
EP
R ES
S BOLT
Clutch Assembly
TU
RN
Flywheel bore
80
Service Procedure
Stamped Angle Spring 1401 Clutch - Remove

Procedure1. Remove the transmission, supporting its weight to prevent damage to the bearing and discs. Install two wooden spacers 1 - 1- 1/2 thick between release bearing and cover assembly. Remove the clutch from the flywheel.
2.
3.
81
Service Procedure
1
Service Procedure
Stamped Angle Spring 1401 Clutch Removal
82
Service Procedure
Stamped Angle Spring 1401 Clutch - Install

Procedure1. Remove the old pilot bearing and wipe all surfaces that will contact the gauging. Secure the dial indicator to the flywheel housing with the gauge finger near the outer edge of the flywheel. 8. 3. Use a soapstone to mark the high and low spots as you rotate the flywheel one (1) revolution. The difference between these two spots should be .008" (0.2 mm) or less. With the dial indicator still secured to the flywheel housing, continue the inspection process by moving the gauge finger so it contacts the pilot bearing bore surface. Rotate the flywheel one (1) revolution. The maximum allowed run out must be .005" (0.13 mm). Secure the dial indicator to the crankshaft with the gauge finger against the flywheel housing pilot area. 7. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Secure the dial indicator to the flywheels outer diameter and move the gauge finger until it contacts the face of the flywheel housing. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. CAUTION: If the above four (4) limits are exceeded, the problem must be corrected. Misalignment will cause damper failure and wear to drivetrain components. 10. Install a new pilot bearing. Eaton strongly recommends the use of a premium grade pilot bearing. The bearing must have a press fit. CAUTION: Tap on the outer race only. Tapping the inner race could cause damage to the pilot bearing.
2.
9.
4.
5.
6.
83
Service Procedure
1
2
3
4
6
5
7
8
9
10
84
Stamped Angle Spring 1401 Clutch Installation
Service Procedure
Stamped Angle Spring 1401 Clutch - Install, Cont

11. Check the following items for wear replace any worn components: a. Cross-shafts and bushings 12. Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening and not interfere with flywheel mounting bolts.
Note: This applies only if a clutch brake is used (non-synchronized transmission). A worn/rough bearing retainer cap may cause the newly installed clutch brake to wear prematurely. Also, excess wear at either the transmission bearing retainer cap (arrow C) and/or the release yoke fingers (arrow B) may prevent the linkage from obtaining a sufficient amount of clutch brake squeeze (Recommended range is 1/2" 1" (13 24mm). Refer to arrow G concerning the nominal distance between the input shafts end and the bearing retainer cap. d. Splines on the input shaft
85
Service Procedure
11A Check Cross-Shafts and Bushings 11B
Check Release Yoke Fingers
Service Procedure
11E Check Smooth Area of Input Shaft for Wear/Roughness Stamped Angle Spring 1401 Clutch Installation
86
Service Procedure

13. Insert two (2) 3/8" x 16 thread x 3" (76 mm) long guide studs into the two upper mounting holes of the flywheel. 14. Install the disc by inserting the aligning tool through the disc splines and then into the pilot bearing. Note: Make sure the side marked Pressure Plate Side faces the pressure plate. 15. With the aligning tool still in place, carefully slide the clutch assembly over the aligning tool and the two (2) guide studs with the Kwik-Adjust aligned with the access hole in the bell housing. 16. Start six (6) 3/8" Grade 5 or better mounting bolts and hand tighten. Remove the two (2) guide studs and replace with the remaining mounting bolts. Using a torque wrench, progressively tighten the eight (8) mounting bolts to 30 35 lbs. ft. (40 47 Nm) of torque using the following criss-cross pattern. Starting at lower left. As the clutch is torqued to the flywheel the shipping bolts may fall out. If not, remove the shipping blocks from between the release bearing and the cover assembly. CAUTION: Failure to tighten these bolts in this manner can: Prevent the clutch cover from centering into the pilot area of the flywheel. Cause permanent damage to the clutch cover (i.e. become cracked or broken). Cause the clutch assembly to be out-of balance with the flywheel. 17. Remove the aligning tool. 18. Shift the transmission into gear. Note: If a clutch brake is used, be sure to install it on the input shaft of the transmission at this time. 19. Position the transmission so that it is both square to and aligned with the engine.
87
Service Procedure
14 13
Insert 2 Guide Studs Insert the Aligning Tool Through Release Bearing Sleeve
Guide Studs
Aligning Tool
2 7
Service Procedure
4 8
16
17
SHIFT INTO GEAR
18
Shift Transmission into Gear Stamped Angle Spring 1401 Clutch Installation
19
Alugn the Transmission to the Engine
88
Service Procedure

20. While moving the transmission forward, rotate the output shaft of the transmission until the splines of both the input shaft and the disc(s) mesh with each other. While performing this task, you must also ensure that the yoke fingers remain in the up position until they can be rotated over the release bearing housing into their final position. CAUTION: Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position. CAUTION: Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and make any necessary changes. CAUTION: If the input shaft will not slide into the discs, they may need to be repositioned. Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch will not release. 21. Install the transmission mounting bolts and torque to the proper specification. 22. Set bearing position. Set the distance between the bearing and clutch brake .500" .562" (13 14 mm). Note: This dimension is critical, do not set less than .500" (13 mm) or more than the .562" (14 mm) under any circumstances. a. b. Use the internal adjustment on the clutch to move the bearing. Put slight tension on linkage to insure that bearing is stretched and no movement toward engine is noticed. Measure with an inside caliper to prevent moving the bearing toward engine. 23. Adjust clutch brake and truck linkage. (Do not change the bearing position by the internal clutch adjustment.) a. Insert a .010" (.25 mm) feeler gauge between the release bearing and clutch brake. Push the pedal down to verify that the linkage moves the release bearing enough to clamp the feeler gauge. The linkage should be adjusted to allow clamp up of the feeler gauge with the pedal down (1/2" [13 mm] from floor) and to release the feeler gauge when the pedal is not over 1" from the floor.
b.
24. If a clutch brake is not used: a. Measure between release bearing and transmission bearing cap with inside calipers with the clutch engaged (pedal up). Read inside calipers with dial calipers. Depress clutch pedal. Measure between release bearing and transmission bearing cap with inside calipers. Subtract this measurement from first measurement. The difference is your release bearing travel. If the release bearing contacts the transmission bearing cap when the clutch is released, the first measurement (a) is your release bearing travel.
b. c. d. e. f.
b.
c.
89
Service Procedure
.500" (13mm) Adjust Internally Clockwise - moves the bearing toward the transmission (decrease gap) Counterclockwise - moves the bearing toward the engine (increases gap) Kwik Adjust - push in and turn Easy pedal (2 1/3 rotations = 1/8") Easy pedal 2000 (1 rotation = 1/8") Fork Style - remove fork and move lugs
.500" .5625" (13mm 14mm)
22 20
Mesh Input Shaft and Disc(s) by Rotating Output Shaft Set Bearing Position
Release Yoke (Clutch Pedal in the Up Position)
Clutch Cover Finger
Service Procedure
Transmission
1/2" - 1" (13 - 25mm)
Yoke Gap 1/16" minimum (1.6mm) Release Bearing Travel (Position)
.010 Feeler Guage
23
Adjust Clutch Brake
24
If No Clutch Brake
25
Check Free Pedal Stamped Angle Spring 1401 Clutch Installation
90
Service Procedure
Eaton Fuller Stamped Angle Spring 1402 Clutches

When fully assembled, the 14" clutch weighs approximately 100 pounds (68 kg). A hydraulic clutch jack is recommended.
Required Tools
Specifications
Essential Steps
None
ENGINE
Clutch
Transmission
91
Service Procedure
Service Procedure
EP
R ES
S BOLT
Clutch Assembly
TU
RN
Flywheel bore
92
Service Procedure
Stamped Angle Spring 1402 Clutch - Remove

2.
3.
93
Service Procedure
1
Service Procedure
Stamped Angle Spring 1402 Clutch Removal
94
Service Procedure
Stamped Angle Spring 1402 Clutch - Install

Procedure1. Remove the old pilot bearing and wipe all surfaces that will contact the gauging. Secure the dial indicator to the flywheel housing with the gauge finger near the outer edge of the flywheel. 8. 3. Use a soapstone to mark the high and low spots as you rotate the flywheel one (1) revolution. The difference between these two spots should be .008" (0.2 mm) or less. With the dial indicator still secured to the flywheel housing, continue the inspection process by moving the gauge finger so it contacts the pilot bearing bore surface. Rotate the flywheel one (1) revolution. The maximum allowed run out must be .005" (0.13 mm). Secure the dial indicator to the crankshaft with the gauge finger against the flywheel housing pilot area. 7. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. Secure the dial indicator to the flywheels outer diameter and move the gauge finger until it contacts the face of the flywheel housing. Use a soapstone to mark the high and low spots while you rotate the flywheel one (1) revolution. The total difference between the high and low spots should be .008" (0.2 mm) or less. CAUTION: If the above four (4) limits are exceeded, the problem must be corrected. Misalignment will cause damper failure and wear to drivetrain components. 10. Install a new pilot bearing. Eaton strongly recommends the use of a premium grade pilot bearing. The bearing must have a press fit. CAUTION: Tap on the outer race only. Tapping the inner race could cause damage to the pilot bearing.
2.
9.
4.
5.
6.
95
Service Procedure
1
2
3
4
6
5
7
8
9
10
96
Stamped Angle Spring 1402 Clutch Installation
Service Procedure

11. Check the following items for wear and replace any worn components: a. Cross-shafts and bushings 12. Verify diameter of the flywheel cavity (this is the recessed area for the flywheel mounting bolts). The damper spring section must fit inside the opening and not interfere with flywheel mounting bolts.
97
Service Procedure
Service Procedure
11E Check Smooth Area of Input Shaft for Wear/Roughness Stamped Angle Spring 1402 Clutch Installation
98
Service Procedure

13. Insert two (2) 3/8" x 16 thread x 3" (76 mm) long guide studs into the 11 and 1 oclock positions. 14. Install the Flywheel Side disc and then install the intermediate plate and adapter ring assembly over the guide studs. The four (4) through holes at the drive straps are the pilot holes for the adapter ring. Note: Make sure the side marked Pressure Plate Side faces the pressure plate. (DRIVE STRAPS MUST FACE PRESSURE PLATE.) Raise the front disc to fit into the intermediate plate opening. 15. Install the rear disc by inserting the aligning tool through both splines and into the pilot bearing. Note: Make sure the rear disc marked Pressure Plate Side faces the pressure plate. Note: When installing this rear disc make sure the ceramic buttons of the discs are stacked/aligned so that they roughly cover each other when sandwiched the intermediate plate. This will aid the pin separator function. 16. With the aligning tool still in place, carefully slide the clutch assembly over the aligning tool and the two (2) guide studs with the Kwik-Adjust aligned with the access hole in the bell housing. 17. Start six (6) 3/8" Grade 5 or better mounting bolts and hand tighten. Remove the two (2) guide studs and replace with the remaining mounting bolts. Using a torque wrench, progressively tighten the eight (8) mounting bolts to 30 35 lbs. ft. (40 47 Nm) of torque using the following criss-cross pattern. Starting at lower left. As the clutch is torqued to the flywheel the shipping bolts may fall out. If not, remove the shipping blocks from between the release bearing and the cover assembly. CAUTION: Failure to tighten these bolts in this manner can: Prevent the clutch cover from centering into the pilot area of the flywheel. Cause permanent damage to the clutch cover (i.e. become cracked or broken). Cause the clutch assembly to be out-of balance with the flywheel.
18. Remove the aligning tool. 19. Shift the transmission into gear. Note: If a clutch brake is used, be sure to install it on the input shaft of the transmission at this time.
99
Service Procedure
13
14
Guide Studs
Buttons
Service Procedure
15
16
Slide Cover Assembly Over Aligning Tool and Guide Studs
2 7
4 8 1 5
SHIFT INTO GEAR
17
Start 8 Mounting Bolts Replacing the 2 Guide Studs Stamped Angle Spring 1402 Clutch Installation
19
100
Service Procedure

20. Position the transmission so that it is both square to and aligned with the engine. 21. While moving the transmission forward, rotate the output shaft of the transmission until the splines of both the input shaft and the disc(s) mesh with each other. While performing this task, you must also ensure that the yoke fingers remain in the up position until they can be rotated over the release bearing housing into their final position. CAUTION: Do not use the cross-shaft release lever (or a pipe over it) to pull the transmission into its final position. CAUTION: Do not excessively force the transmission into the clutch assembly or engine housing. If it does not enter freely, investigate the cause of the problem and make any necessary changes. CAUTION: If the input shaft will not slide into the discs, they may need to be repositioned. CAUTION: Do not let the transmission drop or hang unsupported in the driven discs. This can cause the discs to become distorted and the clutch will not release. 22. Install the transmission mounting bolts and torque to the proper specification. 23. Set Bearing Position. Set the distance between the bearing and clutch brake .500" .562" (13 14 mm). Note: This dimension is critical, do not set less than .500" (13mm) or more than the .562" (14 mm) under any circumstances. a. b. Use the internal adjustment on the clutch to move the bearing. Put slight tension on linkage to insure that bearing is stretched and no movement toward engine is noticed. Measure with an inside caliper to prevent moving the bearing toward engine. a. 24. Adjust Clutch Brake. Adjust the truck linkage. (Do not change the bearing position by the internal clutch adjustment.) a. Insert a .010" (.25 mm) feeler gauge between the release bearing and clutch brake. Push the pedal down to verify that the linkage moves the release bearing enough to clamp the feeler gauge. The linkage should be adjusted to allow clamp up of the feeler gauge with the pedal down (1/2" [13 mm] from floor) and to release the feeler gauge when the pedal is not over 1" from the floor.
b.
25. If a clutch brake is not used: Measure between release bearing and transmission bearing cap with inside calipers with the clutch engaged (pedal up). Read inside calipers with dial calipers. Depress clutch pedal. Measure between release bearing and transmission bearing cap with inside calipers. Subtract this measurement from first measurement. The difference is your release bearing travel. If the release bearing contacts the transmission bearing cap when the clutch is released, the first measurement (a) is your release bearing travel.
b. c. d. e. f.
b.
c.
101
Service Procedure
20
Align the Transmission with the Engine
21
.500" (13mm) Adjust Internally Clockwise - moves the bearing toward the transmission (decrease gap) Counterclockwise - moves the bearing toward the engine (increases gap)
Service Procedure
Kwik Adjust - push in and turn Easy pedal (2 1/3 rotations = 1/8") Easy pedal 2000 (1 rotation = 1/8") Fork Style - remove fork and move lugs
.500" .5625" (13mm 14mm)
1/2" - 1" (13 - 25mm)
23
.010 Feeler Guage
24
Adjust Clutch Brake
Release Yoke (Clutch Pedal in the Up Position)
Clutch Cover Finger
Transmission
2 3 4 5 6 7
Yoke Gap 1/16" minimum (1.6mm) Release Bearing Travel (Position)
25
If No Clutch Brake Stamped Angle Spring 1402 Clutch Installation
26
Check Free Pedal
102
Service Procedure
Heavy Duty Resetting Overview

The cover assembly weighs approximately 150 lbs. Use care when handling.
Required Tools
Arbor Press Basic Hand Tools
103
Service Procedure
EP
R ES
S BOLT
Heavy Duty Clutch Exploded View

T
Clutch Assembly
Service Procedure
O
TU R
N
Flywheel bore
104
Resetting Procedure
Solo Heavy Duty Clutch - Resetting

Procedure1. Remove the four (4) shipping bolts - if they have been installed. Support the clutch in an arbor press with the bearing facing down. (Allowing an additional 1 space for the bearing to move down, and allow access to install the four (4) shipping bolts.) Center the ram and press downward on the retainer until it comes to a stop. Lock the ram in position. a. b. Slide the wear indicating tab to the NEW position and hold it in this position with a magnet. Locate four (4) 7/16 x 14 x 1-3/4 UNC, hex head machine screws. Install them into the four (4) cover holes and turn them finger tight. Progressively tighten (no air guns) the four (4) shipping bolts (crisscross pattern) until the face of the pressure plate is 1.75-1.78 below the mounting surface.
2.
3.
c.
Note: You may need to temporarily install slightly longer bolts to allow access of the 1-3/4 shipping bolts. Note: This important step will reset the pressure plate spacers and allow the clutch to release after reinstallation. 4. Reinstall the clutch using the original installation instructions for the Heavy Duty Eaton Fuller Solo or contact the Roadranger Help Desk at 1-800-826-HELP (4357) from anywhere in North America, 24 hours a day.
105
Resetting Procedure
1
Support Clutch in Arbor Press
2
Center the Ram and Press Downward
Resetting Procedure
3
Slide Wear Indicating Tab to NEW Position
Pressure plate 1.75"- 1.78" below mounting surface
Pressure Plate Mounting Surface
4
Reinstall Clutch Heavy Duty Resetting Procedure
106
Service Procedure
Medium Duty Resetting Overview

The cover assembly weighs approximately 85 lbs. Use care when handling.
Required Tools
Arbor Press Basic Hand Tools
107
Medium Duty Clutch Exploded View
Service Procedure
Flywheel Bore
Service Procedure
108
Resetting Procedure
Medium Duty Solo Clutch - Resetting

Procedure1. Remove the four (4) shipping bolts - if they have been installed. Support the clutch in an arbor press with the bearing facing down. (Allowing an additional 1 space for the bearing to move down, and allow access to install the four (4) shipping bolts.) Center the ram and press downward on the retainer until it comes to a stop. Lock the ram in position. a. b. Slide the wear indicating tab to the NEW position and hold it in this position with a magnet. Locate four (4) 3/8 x 16 x 1-1/4 UNC, hex head machine screws. Install them into the four (4) cover holes and turn them finger tight. Progressively tighten (no air guns) the four (4) shipping bolts (crisscross pattern) until the face of the pressure plate is 1/2 below the mounting surface.
2.
3.
c.
Note: You may need to temporarily install slightly longer bolts to allow access of the 1-1/4 shipping bolts. Note: This important step will reset the pressure plate spacers and allow the clutch to release after reinstallation. 4. Reinstall the clutch using the original installation instructions for the Medium Duty Eaton Fuller Solo or contact the Roadranger Help Desk at 1-800-826-HELP (4357) from anywhere in North America, 24 hours a day.
109
Resetting Procedure
1
Support Clutch in Arbor Press
2
Center the Ram and Press Downward
Resetting Procedure
3
Slide Wear Indicating Tab to NEW Position
4
Reinstall Clutch
Pressure plate 1/2" below mounting surface
Pressure Plate Mounting Surface
Medium Duty Resetting Procedure
110
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111
Copyright Eaton and Dana Corporation, 2002. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.
The Roadranger System is an unbeatable combination of the best products from Eaton and Dana: partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it's backed by the Roadrangers: the most experienced, most expert, most accessible drivetrain consultants in the business. For spec'ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 001-800-826-HELP (4357)) for more time on the road. Or visit our web site at www.roadranger.com.
CLSM-1282 10/02 POD Printed in USA

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Eaton Fuller Clutches

Service Manual CLSM -1282

Notes, Cautions, and Warnings

Preventive Maintenance Overview

Lube Tube Assembly

Lube Tube Lengths

Off highway/severe service - Every 250 hours or once per month.

For additional lubrication information See TCMT-0021 or call 1-800-826-HELP (4357).

Designing a Clutch for a Specific Application

Measure bore size

Why There is No Need to Adjust Eaton Fuller Solo Clutches

Clutch Disc Dampening Characteristics

Clutch Disc Friction Material

Clutch Torque Capacity

Positive Separator Pin

Torque Limiting Clutch Brake

Kwik-Konnect Two-Piece Clutch Brake

Factors that Effect Clutch Performance

When to Inspect the Clutch

Inspection for Clutch Life

Eaton Fuller Solo Heavy Duty 15.5" Clutches

Clutch Exploded View

Driven Disc Driven Disc

Engine Flywheel Intermediate Plate

Solo Heavy Duty 15.5" Clutch - Remove

Solo Heavy Duty 15.5 Clutch Removal

Solo Heavy Duty 15.5" Clutch - Install

Heavy Duty 15.5 Clutch Installation

Solo Heavy Duty 15.5" Clutch - Install, Cont

11A Check Cross-Shafts and Bushings

11B Check Release Yoke Fingers

11C Check Transmission Bearing Retainer Cap

11D Check Splines on the Input Shaft

Solo Heavy Duty 15.5" Clutch - Install, Cont

Solo Heavy Duty 15.5" Clutch - Install, Cont

Solo Heavy Duty 15.5" Clutch - Install, Cont

SHIFT INTO GEAR

STROKE PEDAL 5 TIMES

Eaton Fuller Solo Medium Duty 1401 Clutches

Clutch Exploded View

Clutch Assembly Driven Disc Driven Disc

Engine Flywheel Intermediate Plate

Solo Medium Duty 1401 Clutch - Remove

Solo Medium Duty 1401 Clutch Removal

Solo Medium Duty 1401 Clutch - Install

Solo Medium Duty 1401 Clutch Installation

Solo Medium Duty 1401 Clutch - Install, Cont

11A Check Cross-Shafts and Bushings

11B Check Release Yoke Fingers

11C Check Transmission Bearing Retainer Cap

11D Check Splines on the Input Shaft

Solo Medium Duty 1401 Clutch - Install, Cont

SHIFT INTO GEAR

Solo Medium Duty 1401 Clutch Installation

Solo Medium Duty 1401 Clutch - Install, Cont

Solo Medium Duty 1401 Clutch Installation

Eaton Fuller Solo Medium Duty 1402 Clutches

Clutch Exploded View

Clutch Assembly Driven Disc Driven Disc