4 Set-up and Lubricate

Install a Heavy-Duty 15.5”

Adjust Clutch Linkage

1 Adjust the clutch linkage until the
yoke fingers contact the release
bearing (zero free-play in the cab).
2 Fully press the pedal up to
5 times to move the release
bearing slightly closer to
the transmission and gain
free-play in the cab.
3 Measure the distance between the release bearing Self-Adjusting Clutch
in 4 steps!
and the clutch brake. The correct distance should
be .500" – .560" (12.70 – 14.22 mm)
• If the distance is

1
more than .560"

Transmission
Yoke (14.22 mm) return to Measure
finger Step 1 and readjust
Release

No yoke
bearing
the clutch linkage.

• If the distance is
2 Install Clutch to Flywheel
Release
bearing
gap
.500" – .560"
Clutch
brake
less than .500"
(12.70 mm) consult 3 Install Transmission
x5 Solo Service Manual
(12.70 – 14.22 mm)
(CLSM-0200). 4 Set-up and Lubricate
Eaton Corporation
Verify Clutch Brake Squeeze Clutch Division Eaton® Heavy-Duty 15.5"
201 Brandon Street
4 Insert .010" (.25 mm) feeler 5 Slowly let up on the pedal and Auburn, IN 46706 Self-Adjusting Clutch
gauge between the release check the pedal position at the CLMT-1279
bearing and the clutch brake. moment the gauge can be 03/11 WP Copyright Eaton Corporation, 2001.
Press the pedal down to removed. 1/2" – 1" All rights reserved.
clamp the gauge. (12.7 – 25.4 mm)
• If the pedal is less than 1/2"
• If the gauge Release (12.7 mm) or more than 1"
Clutch (25.4 mm) from the floor
does not clamp, bearing brake
return to Step 1 when the gauge can be Note: Refer to CLSM0200 for clutch removal procedures. Shipping bolts must be used to properly remove the cltuch.
and readjust the removed, readjust the clutch
Feeler

1
clutch linkage. linkage. (Repeat steps
gauge 4 and 5.)
Measure
Verify Free-Play
Measure Engine Flywheel Housing and Flywheel
6 Measure the free-play in the cab. 7 To change the free-play, Engine flywheel housing and flywheel must meet these specifications or there will be premature clutch wear. Remove
The distance must be 1" (25.4 mm) adjust the upper pedal Upper old Pilot Bearing. All gauge contact surfaces must be clean and dry. Use a dial indicator and check the following:
or more. stop to raise or lower pedal
the pedal in the cab. stop
• If the free-play distance is not
1" (25.4 mm) or more, go to
Flywheel Face Runout Flywheel Housing I.D.
Secure dial indicator base to Runout
Step 7 and change the free-play.
1" (25.4 mm) flywheel housing face. Put Secure dial indicator base to
or more gauge finger in contact with crankshaft. Put gauge finger
IMPORTANT: DO NOT RESET THE CLUTCH. flywheel face near the outer against flywheel housing pilot
Do not change free-play by readjusting edge. Rotate flywheel one I.D. Rotate flywheel one
the clutch linkage. revolution. Maximum runout is revolution. Maximum runout is
.008" (.20 mm). .008" (.20 mm).
Lubricate
Use a lithium complex base grease with a minimum of 325° F 8 Apply grease to the
(163° C) operating range meeting N.L.G.I. grade 1 or 2 specs. input shaft and yoke
Pilot Bearing Bore Flywheel Housing Face
9 Apply grease to the Runout Runout
Transmission

Apply ample grease that visibly exits the opening and contacts the
transmission shaft. This will lube the clutch brake when pedal is cross shaft bushings Secure dial indicator base to Secure dial indicator base to
pressed. and linkage pivot flywheel housing face. Position flywheel near the outer edge.
points. gauge finger so that it contacts Put gauge finger in contact with
NOTE: Refer to CLSM0200 for lube hose installation procedures pilot bearing bore. Rotate face of flywheel housing. Rotate
10 Grease release bearing flywheel one revolution. flywheel one revolution.
used with hydraulic clutch release systems.
Maximum runout is .005" Maximum runout is .008"
(.13 mm). (.20 mm).
 2 Install Clutch to Flywheel 3 Install Transmission
Check Transmission For Wear
IMPORTANT: Use the Eaton Clutch Selector Guide Replace any worn components.
(CLSL-1511) to make sure you have the right clutch! Cross Shaft And Bushings
Excessive wear at these points can
Transmission Bearing Retainer Cap cause side loading on the sleeve bushing,
CAUTION: An assembled clutch weighs about 150 lbs. (68 kg).
A worn/rough bearing retainer cap bushing failures and yoke bridge contact
Avoid the risk of injury. Use proper equipment when lifting a clutch.
may cause the clutch brake to wear with the clutch when the pedal is down.
prematurely.
6 Install two
5 Install second 7/6" x 14
1 Measure the 4 Install disc onto UNC x 5" Input Shaft Splines
flywheel bore. intermediate aligning tool. studs into Any wear on the splines will prevent
plate into slots Follow the upper Release Yoke
Use the Eaton 3 Install disc orientation
the driven discs from sliding freely,
Clutch on the clutch mounting Worn fingers can cause causing poor clutch release (clutch
7.0" (8-spring) onto aligning instructions bushing wear and yoke
Selector Guide cover. Flywheel holes. Install drag). Slide discs full length of shaft
8.5" (10-spring) tool. Follow on the disc. interference when
(CLSL-1511) Side must face assembled to check for twisted shaft splines.
10.0" (7-spring, the orientation the pedal is down.
to verify that the flywheel. clutch.
Mack 9-spring) instructions
the damper on the disc.
will fit into the
flywheel bore. Clutch Brake
Input Shaft Replace if worn.
Wear (roughness) can reduce
sleeve bushing life and cause
it to come out. Measure Input Shaft
Length should be 8.657" (219.89 mm) nominal, and not
greater than 8.71" (221.23 mm). Ref. 1990 SAE handbook
4 6 4:36.106. Replace transmission bearing retainer cap if
length is greater than 8.71" (219.89 mm).
8 2
2 Insert aligning tool
through bearing.
Fasten Transmission To Flywheel Housing 3 Position transmission so it is
square to and aligned with engine.

1 7 2 Make sure that the yoke

fingers remain in the up
5 1 Put transmission position until they are over
3 in gear. Be sure the release bearing housing.
9 Remove four yellow new clutch brake
has been installed.
shipping bolts in a
crisscross pattern.

10 Remove the
aligning tool.
7 Install lock washers and mounting
bolts (7/16" x 14 UNC x 2 1/4"
grade 5) finger tight. Replace
studs with lockwashers and bolts.
Pin
8 Progressively tighten mounting bolts 4 Mesh splines by moving transmission
in a crisscross pattern starting with a forward and rotating the output shaft.
lower bolt. Torque to 40–50 lbs. ft. Do not use excessive force. Do not let
11 For 2-Plate Only: the transmission hang unsupported in
Use a 1/4" flat nose punch to lightly tap four the discs.
intermediate plate pins toward the flywheel. 5 Install mounting bolts and
Only part of the pin should be visible. torque to OEM specs.
CAUTION: Do not pull on release arm to install transmission.
This will cause the clutch to over adjust.