Eaton Medium and Heavy Duty Diaphragm Spring Clutches Installation Guide

1. Preparation of Clutch

This section details the preparation steps for the clutch, including optional configurations for release bearings.

1.A Optional: For Clutches with Release Bearing not attached to Cover Assembly

The Release Bearing will be installed on the transmission and clipped after transmission installation.

1.B Optional: For Clutches with Release Bearing permanently attached to Cover Assembly

No action is needed. The Release Yoke will be installed to the Release Bearing during transmission installation.

2. Preparation of Transmission

Proper preparation of the transmission is crucial for clutch installation.

1. Check compatibility

   Verify the compatibility of the transmission Input shaft and the Driven Disc spline dimensions. Ensure they match.

2. Inspect components

   Ensure all mating components of the Clutch and the entire clutch actuation system are inspected. Replace worn components as needed. Wear of components may cause incomplete Clutch disengagement.

3. Check Input shaft

   Ensure the Input shaft is not twisted. The Driven Disc should slide freely on the Input shaft spline. Excessive wear on the Input shaft could lead to poor release or damage to the Driven Disc hub.

4. Ensure fitment

   Ensure the Release Bearing fits the Release Yoke and Input shaft quill, or ensure the Clutch Actuator fits the Clutch (for Push type clutches).

5. Clean and grease surfaces

   Clean surfaces carefully before applying grease. Apply a light layer of grease inside the Clutch disc hub spline and on the splines of the transmission Input shaft. Wipe off excess grease from the transmission Input shaft and the Driven Disc hub spline.

   Important: For dusty environments (Middle East, construction vehicles), it is recommended not to apply grease on the hub or Input shaft splines. Do not apply grease on nickel-coated splines.

   Important: Use the Eaton Clutch Reference Catalogue on the Eaton Website to ensure you have the correct replacement clutch for the vehicle.

   Important: Use industry-accepted spline grease that is temperature resistant, can endure high surface loading, does not become liquid, solid or resinous, meets NLGI consistency class No. 2 (or equivalent), is lithium-based, and not copper-based.

3. Installation of Clutch on Flywheel

This section details the process of installing the clutch onto the flywheel.

1. Verify fitment and inspect pilot bearing

   Before installation, verify the Cover Assembly fits the engine Flywheel. Check that the Driven Disc damper section fits the Flywheel bore and does not interfere with Flywheel bolts. Inspect the pilot bearing for replacement.

2. Check Flywheel flatness

   Important: Check for Flywheel flatness. The Flywheel must be new or resurfaced before Clutch installation. Flywheel face maximum runout should be 0.20 mm (0.008 in). Flywheel to flywheel housing max runout should be 0.20 mm (0.008 in).

3. Check Driven Disc markings

   Check for "Flywheel side" markings on the Driven Disc. Insert Guide Studs into the Flywheel at the positions shown. Insert the Aligning Tool through the Driven Disc and into the pilot bearing. Then, install the Cover Assembly onto the Guide Studs. Use a brass or plastic hammer to lightly tap the Cover Assembly to fully seat it on the Flywheel.

4. Install bolts

   Install bolts per truck manufacturers' recommendations:

   • 362 mm: 9 bolts M8x1.25
   • 365 mm: 9 bolts M8x1.25
   • 380 mm and 395 mm: 8 bolts M10x1.5
   • 400 mm and 430 mm: 12 bolts M10x1.5

   Important: Use only new bolts with the proper length to assemble the Clutch. See OEM service manuals for service recommendations.

5. Tighten bolts

   Tighten the bolts in a criss-cross pattern as shown in the picture and torque to OEM specification. Recommended mounting bolts grade: 10.9.

6. Optional: For Clutches with Shipping Clips

   Be aware that 4 shipping clips (yellow) will come loose while tightening the bolts. Remove the Aligning Tool and the 4 shipping clips.

   Important: Optional For Twin plate Clutches only! Do not disassemble or modify the Cover Assembly! Do not loosen the bolts fastening the intermediate plate! Do not change factory settings!

4. Installation of Transmission

This section covers the installation of the transmission onto the clutch assembly.

1. Install Transmission

   Install the Transmission onto the engine Flywheel Housing, aligning the Input shaft spline with the Driven Disc hub spline. The transmission should slide without force into the Clutch and pilot bearing.

   Important: Optional Release Bearing assembly middle tab must point up.

2. Optional: Release Bearing Check

   On models with Release Bearing attached, ensure the Release fork rotates around the Release Bearing. After mating the Yoke and Release Bearing, check the Yoke position per Transmission specification. For clutches with a quick-connect Release Bearing, use the Yoke to install the Release Bearing. A clear "click" should be heard. If no clear "click" is heard, potential Clutch engagement or disengagement problems may occur.

3. Optional: Push type clutches with CPCA

   For Push type clutches with Concentric Pneumatic Clutch Actuator (CPCA), refer to CLIG-0060 for installation details.

4. Insert and tighten mounting bolts

   Insert and tighten mounting bolts per OEM torque specification. Important: See OEM service manuals for installation recommendations!

5. Important: Optional Applies to all AMT!

   After the Eaton clutch and transmission are installed, it is necessary to perform a Clutch Engagement Point Calibration using the OEM or an approved diagnostic software!

6. Important: Optional for Push type Self Adjust Clutches

   Ensure that the Control Fingers (4 locations on the Cover Assembly) for the Self Adjust system are mated to a Flywheel surface after tightening the Clutch mounting bolts. Use a 0.2 kg (6 ounce) hammer and a 9.5 mm (3/8 in) flat nose brass punch to lightly tap the four Control Fingers to the Flywheel.

   Ensure that the four copper coated Control Fingers are not damaged during assembly to the Flywheel. Do not hit this part when placing the Clutch on Guide Studs. Damage to any Control Finger will decrease the Clutch wear life!

   Ensure that the four copper coated Control Fingers are not damaged during assembly to the Flywheel. Do not hit this part when you place the Clutch on Guide Studs. Damage of any Control Finger will decrease the Clutch wear life!