Clutch Assembly Replacement (6.6L/7.2L w/RPOs MZE, MPK)
Clutch Assembly Replacement (6.6L/7.2L w/RPOs MZE, MPK)
Tools Required
* J 26455-A Clutch Alignment Arbor
* J 35990 Clutch Alignment Arbor
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement Transmission Replacement in Manual Transmission - Medium Duty.
2. Remove the clutch pressure plate bolts and washers.
3. Remove the clutch pressure plate (1).
4. Remove the clutch driven plate (2).
5. Remove the clutch intermediate plate (3).
6. Remove the clutch front drive plate (4).
7. Remove the clutch pilot bearing (5), if necessary.
Inspection Procedure
1. Remove any grease, dirt or oil from the flywheel surface.
2. Inspect the following items for wear:
* Smooth are of the input shaft (1)
* Cross-shafts and bushings (2)
* Splines on the input shaft (3)
* Transmission bearing retainer cap (4), this only applies if equipped with a clutch brake
* Release yoke fingers (5)
3. Inspect the mating surfaces of the engine and bellhousing (1, 2), replace as necessary.
Installation Procedure
1. Install the clutch pilot bearing, if necessary.
Important: Ensure that the side marked "Flywheel Side" faces the flywheel.
2. Install the clutch driven rear plate by inserting the J 26455-A or J 35990 (1) through the plate splines and into the pilot shaft.
3. Install two 3/8 x 16 x 3 inch long guide studs (1).
Important: Ensure that the side marked "Pressure Plate Side" is facing the pressure plate.
4. Install the clutch intermediate plate over the studs and forward until the plate touches the flywheel.
5. Remove the J 26455-A or J 35990 .
Important: Ensure that the side marked "Pressure Plate Side" is facing the pressure plate.
6. Install the J 26455-A or J 35990 through the splines of the clutch driven rear plate, and insert the J 26455-A or J 35990 with the rear plate into the pilot bearing.
7. Ensure that the ceramic buttons (1) align with each other as closely as possible, in order to aid the function of the positive roll pins.
8. Slide the pressure plate over both the guide studs and the J 26455-A or J 35990 , until it rest against the intermediate plate.
9. Install six clutch pressure plate bolts (with washers) until finger tight.
10. Remove the two guide studs, and install the final two clutch pressure plate bolts (with washers) finger tight.
Notice: Refer to Fastener Notice in Cautions and Notices.
11. Tighten the clutch pressure plate bolts, in the sequence shown.
1. Tighten the clutch pressure plate bolts a first pass to 20 Nm (15 lb ft).
2. Tighten the clutch pressure plate bolts a final pass to 40 Nm (30 lb ft).
12. Remove the J 26455-A or J 35990 .
13. Using a hammer and a flat nose punch, lightly tap the four roll pins through the access holes (shown) of the clutch cover.
14. Ensure that the roll pins are against the flywheel, this will allow an equal gap on all sides of the intermediate plate during clutch disengagement.
Important: The roll pins may be damaged of struck with excessive force.
15. Only a small portion of the roll pin (2) will be visible through the access hole (1) of the pressure plate (3).
16. When installed correctly, and the roll pins (2) are correctly positioned, there should be a gap (4) between the roll pin and the pressure plate (6). This will allow the intermediate plate (5) to move back and free the front disc.
Gap between roll pin and clutch cover 0.5 - 0.8 mm (0.020-0.030 in).
17. Install the transmission. Refer to Transmission Replacement Transmission Replacement in Manual Transmission - Medium Duty.
18. Reset the clutch. Refer to Clutch Assembly Adjustment (Resetting procedure in vehicle) Clutch Assembly Adjustment (Resetting procedure in vehicle)Clutch Assembly Adjustment (Resetting procedure out of vehicle) Clutch Assembly Adjustment (Resetting procedure out of vehicle)Clutch Assembly Adjustment (Internal ) Clutch Assembly Adjustment (Internal ).