Clutch Assembly Replacement (6.6L/7.2L w/RPOs MTD)

Clutch Assembly Replacement (6.6L/7.2L w/RPOs MTD)

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 (3).
5. Remove the clutch pilot bearing (4), 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.
2. Install two 3/8 x 16 x 3 inch long (76 mm) guide studs (1) at the 11 o'clock and 1 o'clock positions on the flywheel.




3. Apply lubrication to the hub splines.
4. Install the J 26455-A or J 35990 (1).

Important: Ensure that the side marked "Pressure Plate Side" faces the pressure plate.


5. Install the driven plate by sliding the plate over the J 26455-A or J 35990 (1) splines and into the pilot bearing.
6. Install the clutch pressure plate over the J 26455-A or J 35990 (1) and the guide studs.




7. Install six clutch pressure plate bolts (with washers) until finger tight.
8. 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.

9. 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).





Important: Save these bolts for future use. Should the clutch need to be removed and then re-installed, the shipping bolts must be re-installed (snugly) prior to the clutch removal. If the clutch has been removed, the clutch must be reset.


10. Using a hex-head socket, remove the four yellow colored shipping bolts in a criss-cross pattern.




11. Remove the J 26455-A or J 35990 (1).
12. Install the transmission. Refer to Transmission Replacement Transmission Replacement in Manual Transmission - Medium Duty.
13. 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 ).