Eaton Fuller Pull-Type Clutches
Contents
1. 0 145 inch 3 7 mm end If it fits loosely the gap is too wide and link age adjustment is needed For instruc tions see Section 25 02 6 2 Ifthe blue 0 145 inch 3 7 mm end can t be inserted in the gap then try to insert the green 0 105 inch 2 7 mm end If the green end of the tool fits snug or loose then no adjustment is needed 03 26 96 580132 A 0 105 inch 2 7 mm B 0 145 inch 3 7 mm Fig 8 Inspection Tool A0Q2 12254 6 3 If the green end of the tool can t be in serted in the gap the gap is too narrow and linkage adjustment is needed For instructions see Section 25 02 Adjustment Angle Spring and Easy Pedal clutches are adjusted with either a lockstrap Fig 9 or with the Kwik Adjust mechanism Fig 10 03 01 94 1 Adjusting Ring 2 Lockstrap f250005a Fig 9 Clutch Equipped with a Lockstrap 100 4 Business Class Trucks Service Manual Supplement 31 October 2004 Eaton Fuller Pull Type Clutches 03 01 94 f250162a Fig 10 Clutch Equipped with Kwik Adjust Clutches with a Lockstrap 1 Turn the engine flywheel until the lockstrap is aligned with the clutch inspection cover opening See Fig 1 and Fig 9 Remove the lockstrap See Fig 9 Release the clutch by depressing the pedal Block the pedal in the released position or have someone assist you by holding the pedal down during the adjustment procedure 4 Using a clutch adjusting2. 14 3 mm the adjustment is complete IMPORTANT The clutch will not self adjust if release bearing travel is less than 1 2 inch 12 7 mm 7 Loosen the left side adjuster bolt and rotate the adjuster assembly down meshing the adjuster worm gear with the adjusting ring teeth The ring may have to be moved slightly to allow the worm 25 01 Clutch Adjustments to mesh Install the right side bolt and tighten both bolts 30 to 35 Ibf ft 41 to 47 N m 8 Visually check that the actuator arm is inserted in the release bearing sleeve retainer See Fig 9 If the adjuster assembly is installed correctly the adjuster assembly spring will move back and forth as the clutch pedal is depressed and re leased IMPORTANT The clutch will not self adjust if the actuator arm is not correctly inserted in the release bearing sleeve retainer After making release bearing adjustments check and adjust the clutch linkage For instruc tions see Section 25 02 Business Class Trucks Service Manual Supplement 31 October 2004 100 7
3. Eaton Fuller Pull Type Clutches NOTE The following procedures apply only to Eaton Fuller Easy Pedal and Stamped Angle Spring clutches Solo clutches are adjustment free Release Bearing Travel synchronized transmissions Measurement IMPORTANT Do not skip steps in the adjust ment operations Internal adjustments must be correct before making any linkage adjustments for pedal free play Incorrect adjustments can cause transmission gear clash and slipping and burning of clutch components 1 Apply the parking brakes and chock the front tires 2 Remove the clutch inspection cover from the bot tom of the transmission clutch housing See Fig 1 03 01 94 1 Clutch Inspection Cover f250002a Fig 1 Remove the Clutch Inspection Cover NOTE When checking release bearing clear ance remove the free travel by lightly pulling the release fork against the clutch release bear ing This eliminates any bearing movement 3 Measure the clearance between the release bearing and the clutch cover For a single disc clutch this clearance must be 1 7 8 inch 48 25 01 Clutch Adjustments mm in order for the release bearing to release properly For a dual disc clutch this clearance must be 3 4 inch 19 mm in order for the release bearing to release properly See Fig 2 If the release bearing clearance is not within the specifications then an adjustment is needed Go to Adjustm
4. ct 120 7 Check and adjust the clutch linkage For instruc tions see Section 25 02 Clutches with Kwik Adjust 1 Turn the engine flywheel until the lockstrap is aligned with the clutch inspection cover opening See Fig 1 and Fig 10 2 Release the clutch by depressing the pedal Block the pedal in the released position or have someone assist you by holding the pedal down during the adjustment procedure NOTE An open end wrench is not recom mended for the following step 3 Insert a 12 point 3 4 inch socket or box end wrench through the inspection cover opening Depress the square bolt to adjust the release bearing clearance If clearance between the release bearing housing and the clutch brake is less than 1 2 inch 12 7 mm rotate the adjusting ring counterclockwise to move the release bearing toward the engine If clearance between the release bearing housing and the clutch brake is more than 9 16 inch 14 3 mm rotate the adjusting ring clockwise to move the release bearing toward the transmission Be sure the adjustment bolt is locked when you have completed the adjustment NOTE Each quarter of a turn of the adjustment bolt represents about 0 017 inch 0 4 mm release bearing movement Business Class Trucks Service Manual Supplement 31 October 2004 100 5 25 01 Clutch Adjustments 4 After adjusting release the pedal and check the clearance between the release bearing housing and the forwar
5. d clutch brake disc or torque limiting clutch brake When the clearance is 1 2 inch to 9 16 inch 12 7 mm to 14 3 mm the ad justment is complete 5 Check and adjust the clutch linkage For instruc tions see Section 25 02 Self Adjusting Clutch IMPORTANT The self adjusting clutch normally compensates for wear and should only need adjustment when it is first installed If the release bearing clearance check shows the self adjusting clutch to be out of adjustment be sure that A the actuator arm is correctly inserted into the release bearing sleeve retainer see Fig 11 B the adjuster arm is not bent the release bearing has a 1 2 inch to 9 16 inch 12 7 mm to 14 3 mm travel D other clutch parts such as the adjusting ring aren t frozen or damaged If the clutch is damaged replace it If adjustment is needed do the following 1 Turn the engine flywheel until the adjuster as sembly is in line with the clutch inspection cover opening See Fig 1 and Fig 11 2 Remove the right side bolt from the adjuster as sembly and loosen the left side bolt one turn See Fig 12 3 To allow manual adjustment rotate the adjuster assembly upward See Fig 13 This will disen gage the adjuster worm gear from the adjusting ring Hold the adjuster assembly disengaged and tighten the left side bolt 4 Release the clutch by depressing the pedal block it in this position 5 Using a clutch adjusting tool in th
6. e lower teeth turn the adjusting ring clockwise to move the release bearing toward the transmission or counterclockwise to move the release bearing toward the engine See Fig 11 Eaton Fuller Pull Type Clutches 03 01 94 1 2 Release Bearing Sleeve Retainer Zz 250006a Actuator Arm Fig 11 Correct Actuator Arm Insertion 03 01 94 A Loosen this bolt i B f250007a B Remove this bolt Adjuster Assembly 2 Adjusting Ring Fig 12 Remove the Right Side Bolt 100 6 Business Class Trucks Service Manual Supplement 31 October 2004 Eaton Fuller Pull Type Clutches 03 01 94 Do not pry on the innermost teeth Tighten the bolt Rotate up Use a clutch adjusting tool in the lower teeth f250008a JOP Adjuster Assembly Fig 13 Rotate the Adjuster Assembly CAUTION Do not pry on the innermost gear teeth of the ad justing ring See Fig 13 Doing so could damage the teeth and prevent the clutch from self adjusting NOTE Each lower gear tooth of the adjusting ring represents about 0 010 inch 0 25 mm release bearing movement Thus six notches moved means 0 060 inch 1 5 mm or about 1 16 inch release bearing movement 6 After adjusting release the clutch pedal and check the clearance between the release bearing housing and the forward clutch brake disc or torque limiting clutch brake When the clearance is 1 2 inch to 9 16 inch 12 7 mm to
7. ent in this section 1 10 12 94 Am Je A Release Bearing Clearance Single Disc 1 7 8 inch 48 mm Dual Disc 3 4 inch 19 mm 1 Release Bearing f250198c Fig 2 Release Bearing Clearance 4 Ifthe release bearing clearance measurement is okay check and adjust the clutch linkage For instructions see Section 25 02 Adjustment Angle Spring and Easy Pedal clutches are adjusted with either a lockstrap Fig 3 or with the Kwik Adjust mechanism Fig 4 Clutches with a Lockstrap 1 Turn the engine flywheel until the lockstrap is aligned with the clutch inspection cover opening See Fig 1 and Fig 3 Remove the lockstrap See Fig 3 Release the clutch by depressing the pedal Block the pedal in the released position or have someone assist you by holding the pedal down during the adjustment procedure 4 Using a clutch adjusting tool turn the adjusting ring clockwise to move the release bearing to ward the transmission or counterclockwise to move the release bearing toward the engine Business Class Trucks Service Manual Supplement 31 October 2004 100 1 25 01 Clutch Adjustments 03 01 94 1 Adjusting Ring 2 Lockstrap f250005a Fig 3 Clutch Equipped with a Lockstrap 03 01 94 f250162a Fig 4 Clutch Equipped with Kwik Adjust NOTE Each notch in the adjusting ring repre sents about 0 020 inch 0 5 mm release bearing travel Thus
8. pads 1 Clutch Brake Fig 6 Clutch Travel Adjustments 5 1 Insert the blue 0 56 inch 14 3 mm end If it fits loosely the gap is too wide and ad Business Class Trucks Service Manual Supplement 31 October 2004 100 3 25 01 Clutch Adjustments Eaton Fuller Pull Type Clutches A B A B 03 26 96 580133 A 0 50 inch 12 7 mm B 0 56 inch 14 3 mm Fig 7 Inspection Tool A02 12419 justment is needed Go to Adjustment in this section 5 2 Ifthe blue 0 56 inch 14 3 mm end can t be inserted in the gap then try to insert the green 0 50 inch 12 7 mm end If the green end of the tool fits snug or loose then no adjustment is needed 5 3 Ifthe green end of the tool can t be in serted in the gap adjustment is needed Go to Adjustment in this section IMPORTANT An inspection tool A02 12254 available through the PDCs can be used to check the distance between the release bearing and the release yoke free travel See Fig 6 and Fig 8 The legs on one end of the tool have green tape on them and are 0 105 inch 2 7 mm thick the legs on the other end have blue tape on them and are 0 145 inch 3 7 mm thick 6 If using tool AO2 12254 to check the distance between the release bearing and the release yoke position the tool so it straddles the yoke to ensure that there won t be any misalignment Check the distance with both ends of the tool as follows 6 1 Insert the blue
9. three notches moved means 0 060 inch 1 5 mm or about 1 16 inch release bearing travel 5 After adjusting release the pedal and check the clearance between the release bearing housing and the clutch cover For a single disc clutch when the clearance is 1 7 8 inch 48 mm the internal adjustment is complete For a dual disc Eaton Fuller Pull Type Clutches clutch when the clearance is 3 4 inch 19 mm the internal adjustment is complete 6 Install the lockstrap and tighten the bolt 35 to 40 Ibf ft 47 to 54 N m IMPORTANT Use the same length bolt when installing the lockstrap A longer bolt will lock up the clutch assembly NOTE If the lockstrap will not engage the notches of the adjusting ring check the clutch assembly for worn parts For instructions see Subject 120 7 Ifthe release bearing clearance measurement is okay check and adjust the clutch linkage For instructions see Section 25 02 Clutches with Kwik Adjust 1 Turn the engine flywheel until the lockstrap is aligned with the clutch inspection cover opening See Fig 1 and Fig 4 2 Release the clutch by depressing the pedal Block the pedal in the released position or have someone assist you by holding the pedal down during the adjustment procedure NOTE An open end wrench is not recom mended for the following step 3 Insert a 12 point 3 4 inch socket or box end wrench through the inspection cover opening Depress the square bolt to adj
10. tool turn the adjusting ring to adjust release travel the clearance be tween the release bearing housing and the for ward clutch brake disc If clearance between the release bearing housing and the clutch brake is less than 1 2 inch 12 7 mm rotate the adjusting ring counterclockwise to move the release bearing toward the engine If clearance between the release bearing housing and the clutch brake is more than 9 16 inch 14 3 mm rotate the adjusting ring clockwise to move the release bearing toward the transmission The lockstrap bolt may be installed and used as a fulcrum in turning the adjusting ring NOTE Each notch in the adjusting ring repre sents about 0 020 inch 0 5 mm release bearing travel Thus three notches moved means 0 060 inch 1 5 mm or about 1 16 inch release bearing travel 25 01 Clutch Adjustments 5 After adjusting release the pedal and check the clearance between the release bearing housing and the forward clutch brake disc or torque limiting clutch brake When the clearance is 1 2 inch to 9 16 inch 12 7 mm to 14 3 mm the ad justment is complete 6 Install the lockstrap and tighten the bolt 35 to 40 Ibf ft 47 to 54 N m IMPORTANT Use the same length bolt when installing the lockstrap A longer bolt will lock up the clutch assembly NOTE If the lockstrap will not engage the notches of the adjusting ring check the clutch assembly for worn parts For instructions see Subje
11. transmission clutch housing See Fig 1 3 Slide the clutch brake discs and washer or torque limiting clutch brake tight against the transmission input shaft bearing cap See Fig 5 Also slide the release bearing as far as possible towards the transmission 4 Measure the internal clearance between the aft face of the release bearing and the forward face of the clutch brake disc or torque limiting clutch brake This internal clearance must be 1 2 inch to 9 16 inch 12 7 mm to 14 3 mm in order for the release bearing to release properly See Fig 6 IMPORTANT An inspection tool AO2 12419 available through the PDCs can be used to check the distance between the release bearing and the clutch brake See Fig 7 One end of the tool has green tape on it and is 0 50 inch 12 7 mm in diameter the other end has blue tape on it and is 0 56 inch 14 3 mm in diam eter 5 If using tool AO2 12419 to check the distance between the release bearing and the clutch brake position the tool so that the legs straddle the transmission input shaft Check the gap with both ends of the tool as follows 25 01 Clutch Adjustments 03 01 94 f250003a 1 Transmission Input Shaft Bearing Cap 2 Clutch Brake Discs and Washer Fig 5 Position the Clutch Brake i 1 gt B 08 16 94 f250172b A Release travel 1 2 to 9 16 inch 12 7 to 14 3 mm B Free travel 0 105 to 0 145 inch 2 7 to 3 7 mm between yoke and wear
12. ust the release bearing clearance Rotate the adjusting ring counterclockwise to move the release bearing toward the engine Ro tate the adjusting ring clockwise to move the release bearing toward the transmission Be sure the adjustment bolt is locked when you have completed the adjustment NOTE Each quarter of a turn of the adjustment bolt represents about 0 017 inch 0 4 mm release bearing movement 4 After adjusting release the pedal and check the internal clearance between the release bearing housing and the clutch cover For a single disc clutch when the internal clearance is 1 7 8 inch 48 mm the adjustment is complete For a dual disc clutch when the internal clearance is 3 4 inch 19 mm the adjustment is complete 100 2 Business Class Trucks Service Manual Supplement 31 October 2004 Eaton Fuller Pull Type Clutches 5 If the release bearing clearance measurement is okay check and adjust the clutch linkage For instructions see Section 25 02 Release Bearing Travel nonsynchronized transmissions Measurement IMPORTANT Do not skip steps in the adjust ment operations Internal adjustments must be correct before making any linkage adjustments for pedal free travel Incorrect adjustments can cause transmission gear clash and slipping and burning of clutch components 1 Apply the parking brakes and chock the front tires 2 Remove the clutch inspection cover from the bot tom of the
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