TSI

Number
411-610
Clutch
Spicer

PV776-TSP137697
 Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to January 2000.

The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary ser-
vice bulletins will be issued to cover the changes.

The new edition of this manual will update the changes.

In service procedures where the title incorporates an operation number, this is a refer-
ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-
eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this Service
Documentation:

Note: Indicates a procedure, practice, or condition that must be followed in order to

have the vehicle or component function in the manner intended.

Caution: Indicates an unsafe practice where damage to the product could occur.

Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-
cur.

Volvo Trucks North America, Inc.

Greensboro, NC USA

Order number: PV776-TSP137697

© 2000 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in

retrieval system, or transmitted in any forms by any means, electronic, me-
chanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc..
 Contents
General ........................................................................ 3 Clutch Adjustment (If Wear Tab Does Not Move
Clutch ........................................................................... 3 Freely) .................................................................... 36
............................................................................... 38
Specifications ............................................................. 5
Clutch Pedal Free Play ........................................ 38
Clutch ........................................................................... 5
............................................................................... 38
................................................................................... 5
Clutch Brake Squeeze ......................................... 38
Clutch Component Specifications ............................ 5
Clutch Capacity Selection Chart for Two-Plate Service Procedures .................................................. 39
clutches .................................................................... 7 Transmission, Removal ............................................ 39
................................................................................... 7 Clutch, Replacement ................................................ 39
Spicer Easy-Pedal Clutches ................................... 39
Design and Function .................................................. 9
Removal ................................................................. 39
Clutch ........................................................................... 9
Inspection ............................................................... 40
Clutch Function .......................................................... 9
Installation (Spicer 14 in. Clutch) ........................... 43
Optimum Performance ........................................... 10
Installation (Spicer 15-1/2 in. Clutch) ..................... 46
Terminology ............................................................ 10
Clutch, Replacement ................................................ 50
Guidelines for Proper Maintenance and Operation 11
®
TM
Spicer SAS Clutches .............................................. 50
Spicer Easy-Pedal Clutch .................................... 12
Removal ................................................................. 50
Clutch Selection Data ............................................ 15
Inspection ............................................................... 51
Clutch capacity ..................................................... 15
Installation .............................................................. 53
Option Specifications ............................................. 16
TM
Clutch Adjustment (Synchronized Transmissions
Kwik-Konnect two-piece clutch brake ................ 16
Only) ....................................................................... 55
Torque-limiting clutch brake ................................. 16
TM Clutch, Adjustment ................................................... 56
Kwik-Adjust componentTM ..................................... 16
Explanation of Adjustments ................................... 56
Spicer® 14 in. Easy-Pedal Flat Flywheel
Internal Clutch Adjustment ..................................... 56
Cast-Iron Clutch for Standard 15-1/2 in. Flywheels 17
Normal adjustment ............................................... 56
Positive pin separator .......................................... 17
Free travel setting ................................................ 57
Heavy-Duty Clutches ............................................. 18
Clutch Brake Setting .............................................. 58
Coaxial Springs ...................................................... 18
Adjustment for Synchronized Transmissions
Driven Disc Options ............................................... 19
Without a Clutch Brake .......................................... 58
Ceramic or organic facings .................................. 20
Hydraulic Linkage ................................................... 58
Operating vehicles with ceramic clutch facings ... 21
Slave Cylinder, Adjustment ...................................... 59
Driven-Disc Design ................................................ 21
CAT Engine, Spicer Transmission, SAS Clutch ..... 59
Rolling Resistance ............................................... 22
CAT Engine, Fuller Transmission, SAS Clutch ...... 60
Spicer® SAS Clutch .................................................. 23
Clutch System, Bleeding .......................................... 60
Description ............................................................. 24
Transmission, Installation ......................................... 61
Rolling Resistance, SAS ...................................... 25
System Check ........................................................... 63
Troubleshooting ........................................................ 27
Clutch, Lubrication ................................................... 63
Clutch Troubleshooting ............................................. 27
Spicer Easy Pedal Clutches .................................. 63
Spicer Easy-Pedal Clutch ...................................... 27
Clutch Release Bearings ..................................... 63
Clutch Troubleshooting ............................................. 29
Recommended Change Intervals ........................ 63
Spicer® SAS Clutch ............................................... 29
Recommended Lubricants ................................... 64
Clutch, Adjustment Corrections ............................... 32
Clutch, Lubrication ................................................... 65
VN with Spicer HD Solo Clutch ............................. 32
Spicer SAS Clutches .............................................. 65
HD Solo Clutch Installation Error ........................... 32
Clutch Release Bearings ..................................... 65
Possible Causes: .................................................... 32
Recommended Lubricants ................................... 65
Solution A: .............................................................. 33
Solution B: .............................................................. 34 Operation Numbers

1
2
Group 41 General

General
Clutch

W4000241

Fig. 1: Spicer clutch

Spicer®-manufacturered
This information is provided for TM
clutches—including Easy-Pedal , Solo®, and SAS
clutches.
TM
Spicer Easy-Pedal pull-type clutches include all cast
angle spring pull-type clutches. The primary difference is
the ease of pedal effort. Otherwise, the clutches are ba-
sically the same; minor differences in adjustment are
noted in “Internal Clutch Adjustment” page 56.

Spicer SAS (Stamped Angle Spring) is a non-adjustable

clutch.

3
4
Group 41 Specifications

Specifications
Clutch
Clutch Component Specifications

Subject EP-1402 (14 in., 2-disc) EP-1552 (15 1/2 in., 2-disc)

Minimum bell housing size for mounting No. 2 No. 2

(SAE)

Pilot diameter 374.57–374.65 mm 435.71–435.76 mm

(14.747–14.750 in.) (17.154–17.156 in.)

Bolt circle 394 mm (15.500 in.) 422 mm (16.625 in.)

Flywheel pot depth 75 mm (2 15/16 in.) Flat

Clutch bell to C/L of release yoke

105-C-137 yoke 92 mm (3 3/4 in.) 92 mm (3 3/4 in.)

105-C-64 yoke 104 mm (4 3/16 in.) 104 mm (4 3/16 in.)

New discs only

Disc and ceramic facing thickness (stan- 11.3–11.6 mm (0.445/0.455 in.) 11.3–11.6 mm (0.445/0.455 in.)
dard)

Disc and ceramic facing thickness 9.0–9.3 mm (0.355/0.365 in.) —

(super duty)

Disc and organic facing thickness 11.2–11.7 mm (0.440/0.460 in.) 11.2–11.7 mm (0.440/0.460 in.)

New I/P only

Intermediate plate thickness (standard) 15.9–16.0 mm (0.6250/0.6300 in.) 19.2–19.4 mm (0.7570/0.7620 in.)

Intermediate plate thickness 20.4–20.5 mm (0.8050/0.8100 in.) —

(super duty)

Intermediate plate thickness 20.4–20.5 mm (0.8050/0.8100 in.) —

(14 in. FFW)

Hub spline size 44–254 mm (1 3/4–10 in.) 44–254 mm (1 3/4–10 in.)

(number of splines) 2–10 2–10

Disc assembly max. out-of-flat 1.27 mm (0.050 in.) 1.27 mm (0.050 in.)
(feeler gauge)

Release sleeve 44.3–44.6 mm (1.750/1.754 in.) 44.3–44.6 mm (1.750/1.754 in.)

Bushing diameter 51.00–51.05 mm (2.008/2.010 in.) 51.00–51.05 mm (2.008/2.010 in.)

5
Group 41 Specifications

Subject EP-1402 (14 in., 2-disc) EP-1552 (15 1/2 in., 2-disc)

Intermediate plates, driving lugs to slot 0.152 mm (0.006 in.) 0.152 mm (0.006 in.)
clearance (new min.)

Intermediate plates, driving lugs to slot 0.508 mm (0.020 in.) 0.508 mm (0.020 in.)
clearance (max. worn)

Pressure plates, driving lugs to slot clear- 0.076 mm (0.003 in.) 0.076 mm (0.003 in.)
ance (new min.)

Pressure plates, driving lugs to slot clear- 0.508 mm (0.020 in.) 0.508 mm (0.020 in.)
ance (max. worn)

Pressure plates and pressure plates: out- 0.000–0.102 mm (0.000–0.004 in.) 0.000–0.102 mm (0.000–0.004 in.)
of-flat concave concave

Pin separator gap (new) — 0.584–0.940 mm (0.023/0.037 in.)

Clutch brake-torque limiting torque to rotate 16– 47 Nm (12–35 ft-lb) 16–47 Nm (12–35 ft-lb)

Maximum engine rpm 3300 2600

6
Group 41 Specifications

Clutch Capacity Selection Chart for Two-Plate clutches

Size Clutch Plate Load Cover Assy. Facing Rec. Max. Engine Torque
Color Code
kg (lb) Nm (ft-lb)

14 in. 1,271 (2,800) Red Organic 1,112(820 )

14 in. 1,271 (2,800) Red Ceramic 1,356 (1,000)

(3 buttons)

14 in. 1,453 (3,200) Plain Organic 1,356 (1,000)

14 in. 1,271 (2,800) Red Super-Duty 1,695 (1,250)

Ceramic

(4 buttons)

14 in. 1,453 (3,200) Plain Ceramic 1,898 (1,400)

(4 buttons)

14 in. 1,634 (3,600) Yellow Organic 1,559 (1,150)

15 1/2 in. 1,271 (2,800) Red Organic 1,274 (940)

15 1/2 in. 1,271 (2,800) Red Ceramic 1,627 (1,200)

15 1/2 in. 1,453 (3,200) Plain Organic 1,451 (1,070)

15 1/2 in. 1,453 (3,200) Plain Ceramic 1,898 (1,400)

15 1/2 in. 1,634 (3,600) Yellow Organic 1,695 (1,250)

15 1/2 in. 1,634 (3,600) Yellow Ceramic 2,237 (1,650)

15 1/2 in. 1.816 (4,000) White Organic 1,898 (1,400)

15 1/2 in. 1,816 (4,000) White Organic-10-spring 1,966 (1,450)

Stamped Angle Spring Capacity

SAS Type 1401
Plate Load 12,454 N (2,800 lb)
Spring Color Coded Red
Facing Ceramic
Recommended Torque 757 Nm (560 ft-lb)

7
8
Group 41 Design and Function

Design and Function

Clutch

W4000375

Fig. 2: Clutch

Clutch Function
The clutch transfers power from the engine to the trans-
mission. The transmission input shaft may be stationary
(getting started) or rotating at a different speed than the
engine (upshifting or downshifting). The clutch has
performed its function when both the engine and trans-
mission are rotating at the same speed.

To perform its function, the clutch has discs designed to

slip for a short period of time as spring pressure is ap-
plied, forcing them together. After sufficient pressure is
applied, the discs stop slipping and rotate at the same
speed as the engine.

9
Group 41 Design and Function

Optimum Performance
Optimum performance of Spicer® clutches requires the
following:

• 12–15 mm (1/2–9/16 in.) release travel

• 3 mm (1/8 in.) free travel (clearance between re-

lease bearing and release yoke)

• Clutch-to-brake squeeze must occur 12–25 mm

(1/2–1 in.) from the end of pedal stroke.

Terminology
Release Proper release travel of 12–15 mm
travel (1/2–9/16 in.) ensures that the release
bearing is capable of releasing far
enough to allow the two driven discs to
spin freely and avoid clutch drag.

Clutch free Pedal free play is an indication of clutch

play adjustment interval. When free pedal is
no longer present, begin adjustment
procedures as outlined in “Internal
Clutch Adjustment” page 56.

Clutch free Free travel of 3 mm (1/8 in.) is the

travel clearance between the release yoke
and clutch-bearing wear pads. This di-
mension regulates how much free pedal
is obtained in the cab.

Clutch brake Proper clutch brake squeeze should be

squeeze 12–25 mm (1/2–1 in.) from the end of
the pedal stroke to ensure that the input
shaft will stop rotating when the vehicle
is stationary. The clutch brake is only
used when shifting into first or reverse.
Keep the clutch brake squeeze close to
the end of the pedal stroke to ensure
that it will not be used as an upshifting
brake, which could cause brake life re-
duction.

10
Group 41 Design and Function

Guidelines for Proper Maintenance and Operation

If properly installed, used, and maintained, Spicer®
clutches are designed and built to withstand rugged use.
They will last hundreds of thousands of kimometers
(miles). Almost every early clutch failure can be traced to
excess friction and/or heat, which can be prevented by
proper operation and maintenance. The following is a list
of guidelines.

• Do not ”ride” or ”slip” the clutch. Once a clutch is
fully engaged, there is no heat generated and little
or no wear. However, during the brief period when
the clutch is picking up the load, considerable heat
is generated. By riding or slipping the clutch, the pe-
riod of partial engagement is lengthened, causing
unnecessary heat and wear.
• Always start in the proper gear. An empty vehicle
may be started in a higher gear than a fully loaded
one, but starting in a gear too high for the load may
cause clutch slippage, too much heat, and unneces-
sary wear. Drivers should be trained to use a gear
low enough to prevent excess wear on the clutch. A
gear that will start the vehicle moving with the en-
gine at idle speed is usually correct. If the engine
must be revved up to prevent stalling, the gear se-
lection is too high.
• Do not shift until the vehicle has reached proper
speed. Upshifting before the vehicle has reached
the right speed is almost as bad as starting off in a
gear that is too high. When the difference between
the vehicle speed and the engine speed is too
great, the clutch is forced to slip. The result is extra
heat and wear.
• Never use the clutch to hold a vehicle on a hill. This
requires purposely slipping the clutch which can
generate enough heat to burn up the clutch.
• Never coast with the clutch disengaged. Doing so
can cause clutch failure. The rear wheels drive the
disc through the multiplication of the rear axle and
transmission ratios. This may result in over 10,000
rpm, beyond the burst strength of the facing mate-
rial. Something as simple as coasting down a
loading ramp can burst a driven disc.
• Never engage the clutch while coasting. Doing so
causes tremendous shock to the clutch and the en-
tire drivetrain and may result in internal engine
damage and/or clutch and flywheel failure. Always
report unusual clutch operation promptly. Also, re-
port any change in pedal free travel, slippage, or
any strange feel to the clutch operation. Proper
maintenance, performed on time, will greatly extend
the life of the clutch.

• Match the clutch to the vehicle and the job. Improper

specification may result in a clutch too ”light-duty” for
the job it must perform, resulting in early burnout. It
may be a perfectly good clutch when used in the
application for which it was designed, but totally in-
adequate for heavy-duty use. Mismatching the
clutch to the vehicle is not only bad for the clutch,
but may cause early wear on the whole drivetrain.

11
Group 41 Design and Function
TM
®
Spicer Easy-PedalTM
Clutch
The Easy-Pedal design decreases pedal effort as
much as 50% by the use of assist springs and increases
facing life up to 50% more than other pull-type clutches.
Regular maintenance ensures constant pressure-plate
load regardless of age or wear because of the precise
angle of Spicer’s rugged angular-spring design.
TM
The major components of the Spicer® Easy-Pedal
clutch are the cover assembly and two driven discs sep-
arated by an intermediate plate. They are adjustable,
pull-type clutches of the dry-disc design and have cen-
trally located springs isolated from the heat of the
pressure plate. Dampened driven discs (with springs)
and ceramic facings are considered standard and are
recommended for most applications. Driven discs with
solid centers (rigid) are available.
In the 14 in., two-plate model, the intermediate plate sep-
arating the discs is driven inside by a “pot-type” flywheel
and mounted on six drive pins in the flywheel itself.

In the 15-1/2 in., two-plate model, the intermediate plate

separating the driven discs is driven by four lugs within
the clutch cover assembly. The cover assembly is
mounted on a flat-type flywheel.

All models have four return springs attached to the cover

assembly to retract the pressure plate when the clutch is
disengaged.
TM
Spicer® 14 in. and 15–1/2 in. Easy-Pedal clutches are
available for use on Class 8 trucks with engines up to
600 hp (see “Clutch Capacity Selection Chart for
Two-Plate clutches” page 7 for specific mod-
els/applications).

For detailed illustrations, see:

TM

• Fig. 3: Exploded View of the 14 in. Easy-Pedal

clutch, page 14
• Fig. 4: Exploded
TM
View of the 15–1/2 in.
Easy-Pedal clutch, page 15

Both clutches (14 in. and 15–1/2 in.) offer these advan-
tages:

• Lower pedal effort/bearing load

• Smooth engagement

• Maximum ventilation for cooler operation

• Simplified adjustment

• Direct interchangeability

12
Group 41 Design and Function

TM W4000404

Fig. 3: Exploded View of the 14 in. Easy-Pedal clutch

1 Snap ring 10 Levers (6)

2 Release bearing
TM
assembly 11 Return spring (4)
3 Kwik-Adjust 12 Pressure plate
4 Flywheel ring 13 Anti-rattle springs (Super-Duty only) (3)
5 Assist springs (3) 14 Front disc assembly
6 Release sleeve and bushing assembly (1) 15 Intermediate plate
7 Pressure springs (6) 16 Rear disc assembly
8 Spring pivots (6) 17 Drive pin (6)
9 Adjusting ring

13
Group 41 Design and Function

TM W4000405

Fig. 4: Exploded View of the 15–1/2 in. Easy-Pedal clutch

1 Snap ring 9 Adjusting ring

2 Release bearing
TM
assembly 10 Levers (6)
3 Kwik-Adjust 11 Return springs (4)
4 Flywheel ring 12 Pressure plate
5 Assist springs (3) 13 Front driven-disc assembly
6 Release sleeve and bushing assembly 14 Intermediate plate with positive pin separator
7 Spring pivots (6) 15 Rear driven-disc assembly
8 Pressure springs (6)

14
Group 41 Design and Function

Clutch Selection Data

The proper match of a clutch to a vehicle should be
made by using the formula given, which takes into con-
sideration the gross vehicle weight, engine, transmission,
rear axle, and tires. All of these combined are called the
gradeability factor. For adequate clutch life, the vehicle
must have a gradeability factor of at least 15%. Less
than 15% puts undue stress on the clutch. The grade-
ability factor is determined by using the following formula:

867 x T x R
Gradeability (%) = – Rrg
r x GCW

T: Gross engine torque in ft-lb.

R: Axle ratio x transmission ratio (first gear).

Rrg: Rolling resistance in equivalent grade percent

(see “Rolling Resistance” page 22).

r: Rolling radius of tires.

GCW: Gross Combination Weight in lb.

Clutch capacity
Using the same gross engine torque as used to calcu-
late gradeability, select a clutch using “Clutch Capacity
Selection Chart for Two-Plate clutches” page 7. For
safety, please note these speed limitations:

• 14 in. clutch-Maximum engine speed 3,300 rpm.

• 15-1/2 in. clutch-Maximum engine speed 2,600 rpm.

15
Group 41 Design and Function

Option Specifications
TM
Kwik-Konnect two-piece clutch brake
TM
®
The Spicer Kwik-Konnect two-piece clutch brake is
designed to engage without effort when shifting into re-
verse, low and/or first gears
TM while the truck is at a
standstill. Kwik-Konnect installs easily and provides
cooler operation than competitive clutch brakes.

TM W4001170

Fig. 5: Kwik-Konnect Two-Piece Clutch Brake

Torque-limiting clutch brake

The Spicer® torque-limiting clutch brake not only helps
lengthen the life of the transmission, but has a long life
of its own. Drivers shift easily into first or reverse without
transmission damage or gear clash. The self-contained
torque-limiting feature eliminates the need for special
transmission bearing caps, which are necessary for all
heavy-duty unsynchronized transmissions with pull-type
clutches.

W4001169

Fig. 6: Torque-Limiting Clutch Brake

TM
Kwik-Adjust component TM
®
Spicer 14 in. and 15-1/2 in. Easy-Pedal clutches in-
clude a manual
TM
adjusting easy-lock component. The
Kwik-Adjust component offers the following benefits:

• Quick adjustment
• Easy to reach
• No bolts to remove

Several performance TM advantages are designed into the

Spicer® Easy Pedal clutches. The clutch plate load is
constant and uniform throughout the life of the facing
material. An efficient cover-ventilation design quickly
W4001173
cools the clutch. Because the pressure springs are iso- TM
Fig. 7: Kwik-Adjust Component
lated from the pressure plate (which is the source of
friction heat), they retain their load providing constant
performance over the life of the clutch.

16
Group 41 Design and Function
TM
Spicer® 14 in. Easy-Pedal Flat Flywheel Cast-Iron Clutch
for Standard 15-1/2 in. Flywheels
Spicer® offers a 14 in. cast-iron flat flywheel clutch that
will fit the same flywheel as existing 15-1/2 in. clutchesTM
and without alterations. The Spicer® 14 in. Easy-Pedal
flat flywheel clutch offers the following benefits:

• Maximum engine torque rating of 1,898 Nm (1,400

ft-lb)
• Improved ventilation and heat dissipation over pot-
type clutches
• Standardizes flywheels of fleets
• Greater heat sink, because the thicker pressure
plate and intermediate plate are able to absorb TM W4001171

more heat Fig. 8: 14 in. Easy-Pedal Flat Flywheel

• Best possible engagement characteristics through
the use of the ceramic Super Buttons
• Lug drive
• Spicer® angle-spring design/reliability
• Positive separator

Note: This clutch comes with 14 in. dampened, ceramic,

super-duty discs which may not be mixed or matched
with other discs.

For installation procedures, see “Clutch, Replacement”

page 39.

Positive pin separator

The positive separator improves 14 in. and 15-1/2 in.
flat-flywheel clutch life and performance by providing
cooler operation, smoother engagement, and equal plate
separation.

The separator pin allows the intermediate plate to move

back when the clutch is released, giving equal gap on
both sides of the intermediate plate.

W4001172

Fig. 9: Positive Pin Separator

17
Group 41 Design and Function

Heavy-Duty Clutches TM
The Spicer® Easy-Pedal clutch is available in a 14 in.
Super-Duty model. It offers extra capacity for heavy-duty
conditions on and off highway, and for pickup, and
delivery applications. The Super-Duty has a thicker inter-
mediate plate to absorb and dissipate up to 30% more
heat. Driven discs are faced with four ceramic buttons
per side to provide 33% more friction area.

Coaxial Springs
The coaxial spring (spring-within-a-spring) design in-
creases the life of the clutch and whole drivetrain by
dampening the torsional vibrations inherent in all
drivelines.

W4001174

Fig. 10: Coaxial Spring Design

18
Group 41 Design and Function

Driven Disc Options

Spicer® offers several choices in 14 in. and 15-1/2 in.
driven-disc designs. The proper selection depends on
the operating conditions the vehicle will encounter. The
options are:

• Organic material, rigid

• Organic material, dampened
• Four-button ceramic, rigid
• Four-button ceramic, dampened

W4001175

Fig. 11: Organic Material (Rigid)

W4001176

Fig. 12: Organic Material (Dampened)

W4001177

Fig. 13: 4–Button Ceramic (Rigid)

W4001178

Fig. 14: 4–Button Ceramic (Dampened)

19
Group 41 Design and Function

Ceramic or organic facings

Organic (non-asbestos) facings are offered for lower
horsepower or on-highway applications.
Spicer® recommends ceramic facings (with the Spicer®
button design) for more rugged use, longer life (on or off
highway), and to provide a higher friction coefficient for
more effective engagement and longer facing life.

Spicer® clutches should be replaced when internal ad-

justment cannot correct for a loss of free pedal or cannot
compensate for a slipping clutch.
If clutch replacement is necessary, the transmission
must be removed.

Three-button ceramic facings

Three-button ceramic clutch facings are recommended
to extend the life of 14 in. clutches in vehicles operating
under normal, over-the-road conditions.

W4001179

Fig. 15: Three-Button Ceramic Facings

Four-button ceramic facings

For vehicles such as rear dumps, cement mixers, and
landfill trucks, operating on/off highway, in mud, sand, or
uneven ground, and higher horsepower line-haul applica-
tions, Spicer® recommends the super-duty, four-button
ceramic-facing clutch for long life and high-torque
capacity.

Super damper
The 15-1/2 in. is available with 4 ceramic buttons and 10
coaxial springs with built-in free travel to reduce gear rat-
tle at idle. It is also available with organic facings and 10
coaxial springs.

W4001180

Fig. 16: Super Damper

20
Group 41 Design and Function

Free travel

The disc hub can move 1.5 in either direction before it
engages the dampening springs, thereby reducing gear
rattle when the truck is at idle.

The hub in the super damper can be turned by hand, de-

pending upon the amount of friction lag (it is not loose).

Operating vehicles with ceramic clutch facings

Note: Ceramic facing slip-period is shorter than that for
organic facings.

1 Start the vehicle in first gear.

2 Engage the clutch BEFORE giving the engine any
fuel (engine at idle).
Note: If the driver tries to slip ceramic clutch facings by
raising the rpm with the accelerator and riding, or feath-
ering the clutch pedal, the vehicle will experience erratic
engagement.

Driven-Disc Design
In the past, no one worried about torsional vibration.
Transmissions with 10 or more speeds were split in a
narrow range between 1,800 and 2,100 rpm. Today’s
fuel-efficient engines have high torque and lower-
governed rpm. With fewer speeds in the transmission,
the result is much greater torsional vibration, which
presents a need for finely-tuned dampened discs.

Excessive torsional vibration can significantly shorten the

life of the transmission, prop shaft and axle, and add to
driver discomfort. For maximum service life, rigid discs
are not recommended. Therefore, Spicer® engineered
the Coaxial-Spring (spring-within-a-spring) Driven Disc to
dampen critical vibrations in high-torque-rise engines.
This is available in three models.

• Spicer® 8 (green) coaxial springs are adequate for

engines up to 1,898 Nm (1,400 ft-lb) of torque.

• Spicer® 8 (white) coaxial free-travel springs are ade-

quate for engines up to 1,695 Nm (1,250 ft-lb) of
torque.

• Spicer® 10 (black) coaxial springs are adequate for

engines up to 2,712 Nm (2,000 ft-lb) of torque (only
offered in a 15-1/2 in. disc).

21
Group 41 Design and Function

Rolling Resistance

Road Surface Condition Equivalent Grade %

Concrete Excellent 1

Good 1.5

Poor 2

Asphalt Good 1.25

Fair 1.75

Poor 2.25

Macadam Good 1.5

Fair 2.25

Poor 3.75

Cobbles Ordinary 5.5

Poor 8.5

Snow 50.8 mm (2 in.) 2.5

101.6 mm (4 in.) 3.75

Dirt (smooth) Smooth 2.5

Sandy 3.75

Mud — 3.75 to 15

22
Group 41 Design and Function

Spicer® SAS Clutch

W4001198

Fig. 17: Exploded View of the Spicer SAS Clutch Assembly

1 Pressure plate 10 Washer

2 Adjusting ring 11 Capscrew
3 Lever 12 Snap ring (conventional)
4 Snap ring (conventional) 13 Lock strap
5 Release sleeve bearing (conventional) 14 Lock washer
6 Retainer assembly (conventional) 15 Capscrew
7 Retainer assembly and release sleeve assembly (uni- 16 Release sleeve and bushing assembly (conventional)
tized) 17 Release bearing assembly (unitized)
8 Pressure spring 18 Front driven-disc assembly
9 Flywheel ring assembly

Note: The 1.750 in. 10-spline design has the one-piece

unitized retainer and release sleeve assembly which re-
quires no “snap ring” (12).

23
Group 41 Design and Function

Description
The stamped cover gives the clutch its strength and,
when combined with a flat flywheel, offers a lightweight
package and low inertia.

The strap drive concept reduces pounding and excessive

wear. This clutch incorporates a knife-edge lever design,
producing less friction and greater clutch responsive-
ness. The 356 mm (14 in.) stamped-steel construction is
tailored to mid-range engines having up to 759 Nm (560
ft-lb) of torque capacity with a single plate.

The SAS is a dry disc design with centrally positioned

springs located away from heat generated by the pres-
sure plate.
W4000241
A dampened driven disc (with springs) and ceramic fac- Fig. 18: Spicer Stamped Angle Spring Clutch
ing is provided as standard for this application.

Driven discs with dampened centers and riveted organic

facings are also available.
The flywheel ring carries four drive straps to provide
quiet operation and to retract the pressure plate when
the clutch is disengaged.

The major components of the Spicer SAS Single Plate

Clutch are the cover assembly and a driven disc.

For detailed illustration, see:

• Fig. 17: Exploded View of the Spicer SAS Clutch

Assembly, page 23

24
Group 41 Design and Function

Rolling Resistance, SAS

Road Surface Condition Equivalent Grade %

Concrete Excellent 1

Good 1.5

Poor 2

Asphalt Good 1.25

Fair 1.75

Poor 2.25

Macadam Good 1.5

Fair 2.25

Poor 3.75

Cobbles Ordinary 5.5

Poor 8.5

Snow 50.8 mm (2 in.) 2.5

101.6 mm (4 in.) 3.75

Dirt (smooth) Smooth 2.5

Sandy 3.75

Mud — 3.75 to 15

25
26
Group 41 Troubleshooting

Troubleshooting
Clutch Troubleshooting
Spicer Easy-Pedal Clutch

Before working on a vehicle, set the parking brakes,

place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.

Fault Reason Remedy

Poor clutch release or Clutch adjustment not correct
poor engagement
Flywheel pilot bearing too tight in flywheel or on
end of input shaft
Seized pilot bearing
Non-functioning clutch brake
Damaged clutch release bearing
Clutch-release yoke cross shaft projecting
through the release yoke
Release yoke contacting cover assembly at full
release position
Release yoke not aligned properly with the re-
lease bearing
Intermediate plate sticking on drive pins
(EP-1402 only)
Intermediate plate binding (15 1/2 in. or 14 in.
FFW)
Pressure plate not retracting
Recheck the adjustment per instructions.
Free the pilot bearing so that it goes onto the
input shaft with only a light push. If the bearing
is rough, replace it.
Replace the bearing.
Review the adjustment procedures. Ensure the
torque rotation is 16–47 Nm (12–35 ft-lb).
Replace the bearing. If the bearing is the
greased type, lubricate it with the recom-
mended lube.
Relocate the release shaft so that it does not
protrude out. Check the bell housing bushings
and release the yoke for wear. Lubricate the
bushing.
Replace the release yoke with the proper yoke
and/or adjust the linkage for proper travel.
Inspect the transmission bearing cap for exces-
sive wear.
Check the flywheel. It probably has been resur-
faced more than the 1,5 mm (0.060 in.)
recommended.

Check that the drive pins are 90 square to the
flywheel surface and that there is a minimum
0.152 mm (0.006 in.) clearance between the
drive pins and the intermediate plate slots.
Check that there is a minimum 0.152 mm
(0.006 in.) clearance between drive lugs and in-
termediate plate slots.
Check the pressure-plate drive lugs for a 0.076
mm (0.003 in.) clearance.
Check the pressure plate return springs.
Check the amount of release travel.
The internal lever nose is out of groove.

27
Group 41 Troubleshooting

Fault Reason Remedy

Worn splines on the drive gear of transmission Check the drive gear and the driven discs hubs
Poor clutch release or for excessive wear. Replace if necessary.
poor engagement (con-
tinued) Disc facings gummed with oil or grease Replace the disc. Cleaning is not
recommended. Check for a leak causing con-
tamination.
Broken intermediate plate Replace the entire intermediate plate/driven-
disc assembly. Damage such as this is almost
always caused by abusive use of the clutch.
Hub and input shaft Check for rust, corrosion, burrs, etc.
Improper setting of pin separator (15 1/2 in. or Lightly tap each of the four separator pins in the
14 in. FFW clutches) intermediate plate so that they contact the fly-
wheel.
Bent driven disc Replace the driven disc.
No free pedal Readjust per the pedal instructions.
Clutch slipping
Release mechanism binding Check the release mechanism and linkage. Lu-
bricate them if necessary.
Worn clutch facings Replace the complete disc and check the op-
posing surfaces.
Grease or oil on facings Replace the driven discs.
Check for a leak causing contamination.
Overloaded clutch Check to ensure the proper clutch has been
specified for application.
Clutch release bearing dry or damaged Lubricate the bearing or replace it.
Noisy clutch
Flywheel pilot bearing dry or damaged Replace the bearing.
Clutch release yoke striking flywheel ring Adjust the clutch. Also check the wear on cross
shafts, bell housing bushings, and release yoke
fingers. Replace them if necessary.
Improper clearance between drive slots and The clearance should be no more than 25.9
drive lugs on pressure plates or intermediate mm (1.020 in.) on either component.
plates
Gear rattle, free travel Verify the correct disc.
Clutch disc damper interfacing with flywheel Replace the worn driven discs. Be sure the fly-
mounting bolts wheel bolt head is the correct height and the
discs are installed in the correct positions.

28
Group 41
Clutch Troubleshooting
Spicer® SAS Clutch
Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.
Fault Reason
Flywheel pilot bearing too tight in flywheel or on
Poor Clutch Release end of input shaft
Damaged clutch release bearing
Damaged or seized pilot bearing
Clutch release shaft projecting through release
yoke
Pressure plate not retracting
Release yoke contacting cover assembly at full-
release position. Release yoke not aligned
properly with release bearing
Driven disc distorted
Worn splines on the input shaft of transmission
Disc facings gummed with oil or grease
Broken intermediate plate
Broken or loose motor mounts
Worn pilot bearing
Loose or worn linkage
Loose or worn facings
Excessive engine idle
Troubleshooting
Remedy
Free the pilot bearing to a light push. If bearing
is rough, replace it.
Replace bearing. If bearing is the grease type,
lubricate with a recommended lubricant.
Replace with a new bearing.
Relocate release shaft so it goes through the
release yoke and does not project. Check bell
housing bushings and release yoke for wear.
Check pressure-plate drive straps for proper
tension. Check the amount of release travel.
Replace release yoke with the proper yoke and
thin-headed bolts. Check the flywheel. It may
have been resurfaced more than the 1.5 mm
(0.060 in.) recommended.
Lever nose out of the groove. The lever should
be straight within 0.64 mm (0.025 in.). Replace
it if it cannot be straightened.
Check input shaft and driven disc hub for exces-
sive wear.
Replace entire disc; cleaning is not recom-
mended. Check for leak causing the gumming.
Replace entire intermediate plate/driven disc
assembly. Damage such as this is almost al-
ways caused by abusive clutch use.
Replace or retighten motor mounts.
Replace pilot bearing.
Replace or tighten linkage.
Replace disc assembly.
Adjust engine idle.
29
Group 41 Troubleshooting

Fault Reason Remedy

Release mechanism binding Check the release mechanism and linkage.
Slipping Lube if necessary.
Worn clutch facings Replace facings or complete disc if necessary.
Grease or oil on facings Replace facings.
Check for a leak causing contamination.
Weak pressure springs Replace springs.
Overloaded clutch Check that proper clutch has been specified.
Flywheel burned Check, replace, or regrind the flywheel.
Improper facing material Use correct facing or replace the disc assembly.
Clutch release bearing dry or damaged Lubricate or replace the bearing.
Noisy clutch
Flywheel pilot bearing dry or damaged Replace pilot bearing.
Clutch release bearing housing striking flywheel Replace clutch.
ring
All or part of powertrain out of balance Check each unit individually and recheck power-
Vibration train as a complete assembly.
One or more units in powertrain out of alignment Check and align powertrain. Replace the faulty
component.
Worn input shaft splines Replace input shaft.
Worn crankshaft bearings Replace crankshaft bearings.
Worn or loose engine mounts Replace or tighten the engine mount.
Loose or out-of-balance universal joint or drive- Tighten or replace the universal joint. Check
shaft driveshaft for balance.
Clutch out-of-balance Replace clutch.
Worn disc hub splines Replace disc.
Worn pedal linkage Replace the worn pedal linkage with new link-
Hard pedal age.
Binding in pedal linkage Lubricate and adjust pedal linkage.
Excessive spring pressure in cover assembly Install the proper cover assembly.
Contact pad of release bearing carrier worn by Replace carrier and release yoke. Also check
release yoke for proper hook-up to provide the best linkage
operating positions.
Worn or loose pedal linkage Replace or tighten pedal linkage.
Aggressive
Excessive backlash in powertrain Adjust or replace worn parts.
Warped driven disc Install a new disc assembly.
Worn hub splines Install a new disc assembly.
Worn splines on input shaft Replace input shaft.
Improper facing material Install the proper driven-disc assembly.

30
Group 41
Fault Reason
Loose, broken, or worn engine mounts
Chatter
Pedal linkage worn
Loose or cracked clutch housing
Spring shackles and mountings
Misalignment
Oil or grease on facings
Warped or bent driven disc assembly
Improper disc facing thickness
Worn pilot bearing
Wrong spring pressure in cover assembly
Release levers in clutch cover not parallel
Troubleshooting
Remedy
Tighten or replace engine mounts.
Replace linkage.
Tighten or replace clutch housing.
Tighten or replace loose, worn, or broken
shackles and mountings.
Realign.
Install a new disc assembly.
Check for a leak causing contamination.
Install driven disc assembly.
Install the proper disc assembly.
Replace pilot bearing.
Replace assembly with the proper cover assem-
bly.
Recheck clutch cover installation.
31
Group 41 Troubleshooting

Clutch, Adjustment Corrections HD Solo Clutch Installation Error

• Clutch was recently installed onto engine flywheel.
VN with Spicer HD Solo Clutch
• Clutch is still bolted to engine flywheel.

CAUTION • Release bearing travel (position) is less than 12.4

mm (0.49 in.) see Fig. 19: Clutch, page 32.
When installing a Spicer Solo clutch on a VN series
model, it is important that the installation procedure be • Wear tab moved 19 mm (3/4 in.) or more from
“NEW” position; see Fig. 20: Clutch wear tab, page
followed correctly. If the procedure is not followed, the 32.
clutch may become over-adjusted. This can result in
reduced performance and shortened life of the clutch.

Before working on a vehicle, set the parking brakes,

place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.

W4001445

Fig. 20: Clutch wear tab

Possible Causes:
A. While installing the transmission, the clutch control
arm was used to draw the transmission into the fly-
wheel bell housing pilot, forcing the clutch release
bearing to move rearward. This excessive move-
ment of the bearing caused the Solo to adjust
when no adjustment was required. See “Solution
A:” page 33
B. Solo clutch was not properly reset or caged prior to
removal from engine flywheel. The cam tab and the
W4001444
4 plate spacer roll pins must be reset. See
Fig. 19: Clutch “Solution B:” page 34

1 Release bearing travel (position)

2 Clutch Cover
3 Finger
4 Yoke gap*
5 Release yoke*
6 Clutch brake
*The measurement of the yoke gap and release
yoke can be zero due to the hydraulics of the clutch.

32
Group 41 Troubleshooting

4
Solution A:
1

W4001448

Fig. 23: Pumping clutch pedal

W4001446
Push clutch pedal (compressing the
Fig. 21: Clutch pedal
clutch brake) at least 5 times. This will
Push clutch pedal completely down allow the Solo to automatically reposi-
against the floor and hold it. tion the bearing.

W4001447

Fig. 22: Clutch wear tab

Move the clutch wear tab to a com-

pletely new position.

Note: Tab should move with finger

pressure (it may require use of a mag-
net). Do not force the wear tab to move
by striking or prying it. If the wear tab
does not move with finger pressure,
see “Clutch Adjustment (If Wear Tab
Does Not Move Freely)” page 36.

3
Release clutch pedal, the solo wear
tab is now reset.

33
Group 41 Troubleshooting

Solution B: 4
Special tools: 9996956
1

T2006672
W4001446
Fig. 26: Cranking tool
Fig. 24: Holding clutch pedal
Remove the inspection cover and in- 9996956
Push clutch pedal completely down stall cranking tool 9996956 (Volvo
against the floor and hold it. engine only) to the flywheel housing.
Note: A non-Volvo engine will require
2 a turning tool designed for that partic-
ular engine.

W4001447

Fig. 25: Adjusting clutch wear tab

Move the clutch wear tab to a com-

pletely new position.

Note: Tab should move with finger

pressure. Do not force the wear tab to
move by striking or prying it. If the
wear tab does not move with finger W4001449

pressure see “Clutch Adjustment (If Fig. 27: Installing hex head bolts
Wear Tab Does Not Move Freely)”
page 36. Install 4 hex head bolts (7/16 in.-14 7/16 in.–14
UNC x 1-3/4 in.) through the inspec- UNC x 1-3/4
tion window in the transmission bell in.
3 housing. (You can use the same ship-
Release clutch pedal, wear tab will not ping bolts that were used to cage the
have moved. The Solo wear tab is pressure plate when the clutch was
now reset. shipped.) Turn them finger tight.

34
Group 41 Troubleshooting

6 7

W4001466

Fig. 28: Pressure plate

1 Pressure plate (1.75–1.78 in. below mounting

W4001451
surfact)
Fig. 30: Remove the hex head bolts
2 Pressure plate
3 Mounting surface After all 4 bolts have been installed
correctly, remove the bolts. Check that
there is no gap between the plate
spacer roller pin and the tamper-proof
plate. The plate spacer pins are now
reset.

W4001450

Fig. 29: Pressure plate fully retracted

W4001448
1 Gap approx. 1.6 mm (0.062 in.)
Fig. 31: Pumping clutch pedal
Progressively tighten the bolts in a 1.6 mm
crisscross pattern until the pressure (0.062 in.) Push pedal down (compressing the
plate is fully retracted. The gap under 9996956 clutch brake) a minimum of 5 times to
each tamper-proof plate spacer bolt allow the Solo to automatically reposi-
will be approximately 1.6 mm (0.062 tion the bearing.
in.). To gain access to all 4 locations,
turn the engine over using flywheel
wrench 9996956.

Note: Do not overtighten the bolts. Do

not use a pneumatic ratchet.

35
Group 41 Troubleshooting

Clutch Adjustment 4
(If Wear Tab Does Not Move Freely)
For the wear tab to move freely, the release bearing
must be moved further towards the rear of the truck:

W4001447

Fig. 34: Moving the wear tab

Move wear tab to the new position.

W4001452

Fig. 32: Removing yoke gap

1 No yoke gap

Remove all yoke gap with a temporary

linkage adjustment.

Note: This adjustment is acceptable

only with hydraulic actuation.

2 W4001453

Fig. 35: Adding temporary spacers

1 Temporary spacers
2 Flywheel Housing
3 Bell Housing
4 Transmission

CAUTION
Position a suitable transmission jack under the trans-
mission to support the transmission. Failure to do so
can damage transmission components.
W4001446

Fig. 33: Holding the clutch pedal

If the wear tab still doesn’t move
Push the pedal completely down and freely, loosen all the transmission
hold it. mounting bolts with the clutch linkage
still attached and add temporary spac-
ers (such as washers, 6.4–12 mm
3 [1/4–1/2 in.] thick) between the
The bearing will move further towards flywheel bell housing and the trans-
the rear. mission bell housing.

36
Group 41 Troubleshooting

6 7

W4001447

Fig. 37: Repositioning the wear tab

W4001446

Fig. 36: Holding down the clutch pedal Move the wear tab to the new position.

Push the pedal down and hold, to

draw the clutch bearing back further. 8
Retighten the transmission mounting
Note: The clutch linkage must be able bolts.
to allow for free pedal; see “Clutch
Pedal Free Play” page 38.
9
Check that the release bearing travel 12.4 –14.2
is between 12.4–14.2 mm (0.49–0.56 mm
in.). (0.49–0.56 in.)

37
Group 41 Troubleshooting

Clutch Pedal Free Play Clutch Brake Squeeze

The free movement of the clutch pedal before the re- Clutch brake squeeze is the point at which the clutch
lease yoke finger contacts the clutch release bearing, brake begins to be compressed by the back cover plate
beginning the clutch release process. of the clutch release bearing assembly.

1
Hold a tape measure or ruler firmly
against the floor or seat cushion to
prevent accidental movement.

W4001467

Fig. 39: Measuring clutch brake squeeze

1 Clutch brake squeeze

The clutch brake should begin to be compressed in the

last 25–38 mm (1–1.5 in.) of pedal travel (1).

W4001465

Fig. 38: Measuring clutch pedal free play

1 Clutch pedal free play.

Measure the distance between the

topmost clutch pedal position and the
position where the pedal first meets
resistance. Clutch pedal free play (1)
should be 12–76.2 mm (1.5–3 in.).

38
Group 41 Service Procedures

Service Procedures
4311-01-01-01 2
Carefully pull the transmission back to
Transmission, Removal remove the splined shaft from the
driven discs and the clutch.

4111-03-03-01
Clutch, Replacement
Spicer Easy-Pedal Clutches
W4000161

Fig. 40: Correct transmission alignment

Before working on a vehicle, set the parking brakes,

Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.
place the transmission in neutral, disconnect the bat-
teries, and block the wheels. Failure to do so can
result in unexpected vehicle movement and can cause
serious personal injury or death.
For detailed illustrations, see:
TM

• Fig. 3: Exploded View of the 14 in. Easy-Pedal

clutch, page 14
CAUTION • Fig. 4: Exploded
TM
View of the 15–1/2 in.
Easy-Pedal clutch, page 15
When removing the transmission, use a sling or jack
For lubrication information, see “Clutch, Lubrication”
to maintain alignment. Do not let the rear of the trans-
page 63.
mission drop or hang unsupported in the splined hubs
of the driven discs. Failure to adequately support the
transmission and maintain alignment can damage the Removal
hubs, and can result in poor clutch operation or clutch
release problems. 1

W4000377

Fig. 42: Installing a Spline Aligning Tool

W4000253
Use an old transmission input shaft to
Fig. 41: Disconnecting external clutch linkage install a spline aligning tool through
the release bearing and the driven
Before pulling the transmission free, discs into the pilot bearing.
disconnect the external clutch linkage
and rotate the release yoke so it will
clear the release bearing when it is re-
moved.

39
Group 41 Service Procedures

2 4

WARNING
Be careful to hold both driven disc and intermediate
disc on the aligning tool and the aligning tool in the
pressure plate. This assembly is very heavy, and can
slide off and drop, causing serious personal injury.

5
Take out the remaining bolts and care- 35 kg (75 lb)
fully remove the clutch. 70 kg (150 lb)

Note: A 14 in. clutch assembly weighs

approximately 35 kg (75 lb) and a
W4000378 15-1/2 in. clutch assembly weighs ap-
Fig. 43: Using the Release Tool to Pull Bearing Back proximately 70 kg (150 lb). Therefore,
a hoist may be required to lift them.
Pull the bearing back, using the re-
lease tool shown. Insert two 5/8 in.
spacers between the clutch cover and
the release bearing to relieve the inter- Inspection
nal spring load of the clutch cover and
1
allow for reinstallation.

W4000380

Clutch Housing

Inspect the mating surfaces of the

transmission clutch housing and the
W4000379 engine flywheel housing. Any appre-
Fig. 44: Removing Bolts ciable wear on either housing will
cause misalignment.
Completely remove the top two bolts 3/8-16 UNC x
and install two guide studs: 2 1/2 in.
7/16–14 UNC
14 in. 3/8-16 UNC x 2 1/2 x 5 in.
in.

15–1/2 in. 7/16–14 UNC x 5 in.

40
Group 41 Service Procedures

2 6
Maximum permissible runout is 0.013 0.178 mm
mm per 1 mm (0.0005 in. per 1 in.) of (0.007 in.)
the flywheel diameter. 0.203 mm
(0.008 in.)
Note: The total indicated difference
between the high and low points must
be 0.178 mm (0.007 in.) or less for the
14 in. clutch and 0.203 mm (0.008 in.)
or less for the 15-1/2 in. clutch.

W4000381

Common Wear Areas

Most wear will be found on the lower

half of mating surfaces, with the most
common wear areas between the
three and eight o’clock positions.
W4001183

Securing Dial to the Crankshaft

3
Replace the clutch housing if it is worn. Secure a dial indicator to the crank-
shaft. With the gauge finger against
the housing pilot, rotate the crankshaft.
4

8
Use a marker or piece of soapstone to 0.203 mm
mark the high and low points. (0.008 in.)

Note: The total difference between

the high and low points should not ex-
ceed 0.203 mm (0.008 in.).

W4001182

Securing Gauge to Engine Flywheel Housing

Begin by wiping all surfaces before

gauging. Secure the dial indicator to
the engine flywheel housing with the
gauge finger on the face of the fly-
wheel near the outer edge.

5
Rotate the flywheel.

41
Group 41 Service Procedures

9 Pot-style flywheels only

12

W4001184

Finger of Gauge to Contact Housing

Move the gauge finger to contact the 0.203 mm W4000382

face of the engine flywheel housing.
Again, rotate the crankshaft and then
mark the high and low points.
Note: The total difference between
the high and low points should not ex-
ceed 0.203 mm (0.008 in.).
(0.008 in.) Remove drive pin set screws
Mark the flywheel-to-crankshaft posi-
tion with a piece of soapstone or chalk
and remove the crankshaft bolts. Re-
move the flywheel and set it on a flat
work surface.

10 13
Remove the two set screws from each
of the six drive pins.

WARNING
The drive pins are made of hardened steel and can
chip. Wear safety glasses when removing the old
drive pins.

14
Drive out the old drive pins with a
brass hammer and proceed to
W4001185 “Installation (Spicer 14 in. Clutch)”
Gauge Finger to Contact Pilot Bearing Surface page 43 or “Installation (Spicer 15-1/2
in. Clutch)” page 46.
Move the gauge finger to contact the 0.127 mm
pilot-bearing bore surface. Again, (0.005 in.)
rotate the flywheel. Maximum total al-
lowable runout is 0.127 mm (0.005 in.).

11
If any of the above limits are exceeded,
the problem must be corrected or mis-
alignment will cause premature wear
to the drivetrain components.

42
Group 41
Installation (Spicer 14 in. Clutch)
Fig. 45: Installing Six New Drive Pins
Install six new drive pins in the previ-
ously unused holes in the flywheel.
Space them out equally. Make sure
the shanks of the pins are a press fit
in the flywheel rim.
2 drive slots is 0.152 mm (0.006 in.). If
Spicer® recommends using a drive-pin
aligning tool like the one found in the
Spicer® CSK-1 tool kit. Make sure that
the heads are square with the friction
surface because misaligned drive pins
may cause clutch-release problems.
3 6
Put two small spacers on the friction
surface of the flywheel and carefully
set the intermediate plate over the
drive pins. The spacers will prevent
the intermediate plate from pinching
fingers and give a finger hold when it
is removed.
Service Procedures
4
W4000384
Fig. 46: Turning the Plate
W4000383
Turn the intermediate plate in one di-
rection as far as it will go.
5
Use a 0.006 in. feeler gauge and 0.152 mm
check the clearance between the drive (0.006 in.)
pin and the drive slot. Check the same
side of each pin. The minimum clear-
ance between the drive pins and the
Spicer® the proper clearance is not obtained,
CSK-1 tool kit realign the drive pins and recheck the
squareness. Recheck the clearances.
These checks are necessary to ensure
that the clutch will release properly
when installed.
Do not file the drive pin slots on the in-
termediate plate to obtain correct
clearances. Doing so creates an
unequal load on the pins. This is a fre-
quent cause of poor release or the
clutch not releasing at all. It can also
result in broken drive pins.
43
Group 41 Service Procedures

7 10

W4000382
W4000386
Fig. 47: Reinstalling drive pin set screws
Fig. 48: Disc Against Flywheel
If the alignment and clearance is cor-
rect, lock each of the six pins in place Place the front driven disc against the
with two new 3/8 in. x 3/8 in. set flywheel with the side stamped ” FLY-
screws. WHEEL” facing the engine.

8
Reinstall the flywheel to the engine 11
crankshaft, making sure the chalk
marks are lined up. For flywheel instal-
lation procedure and torque specs,
refer to:

Service PV776 200–000

Manual Engine Specifications

IMPACT Function Group: 2166

Information Type: Re-
pair, Installation
”Flywheel, Installa-
tion“

for installation procedure and torque

specs on the flywheel mounting bolts. W4000387

Fig. 49: Installing the Intermediate Plate

9
Remove the pilot bearing and replace Install the intermediate plate by posi-
it with a new bearing. tioning the drive slots on the drive pins
and remove the aligning tool.

CAUTION
Tap on the outer race of the pilot bearing only, making
sure it is seated properly in the bearing bore. This
bearing must have a press fit within the pilot bearing
bore.
CAUTION
Super-Duty clutches have thicker intermediate plates
and thinner super buttons than standard clutches. Do
not intermix these components.

44
Group 41
12
W4000388
Fig. 50: Installing Anti-Rattle Springs
When installing a Super-Duty clutch,
be sure to install three anti-rattle
springs. Space them equally between
the drive pins with the rounded sec-
tions toward the flywheel face. Wear
safety gloves when installing anti-rattle
springs.
13
Insert the aligning tool through the hub
of the rear disc with the side stamped
”PRESSURE PLATE” facing the
transmission and install it after the in-
termediate plate.
Note: The side stamped ”PRESSURE
PLATE” must face the transmission
and the side stamped ”FLYWHEEL”
must face the engine.
Service Procedures
14
W4000389
Fig. 51: Inserting the Aligning Tool
Reinsert the aligning tool through the
hub of the front driven disc and into
the pilot bearing. The relative position
of the buttons on the front and rear
discs is not important.
15
W4000391
Fig. 52: Positioning the Clutch Cover
Position the clutch cover over the
guide studs installed at the top of the
flywheel.
TM Make sure that the Kwik-
Adjust mechanism is aligned with the
opening of the bell housing of the
transmission.
16
Start six 3/8 in. x 1 1/4 in., Grade 5 or
better, mounting bolts with lock wash-
ers and tighten them finger-tight.
45
Group 41 Service Procedures

17 20
To achieve final torque, progressively 47–54 Nm
tighten all bolts to 47–54 Nm (35–40 (35–40 ft-lb)
ft-lb). As the bolts are tightened, the
wooden spacers should fall out. If they
do not fall free, be sure to remove
them.

21
The aligning tool may have to be
tapped lightly with a mallet to remove
it.

Installation (Spicer 15-1/2 in.

W4000392
Clutch)
Fig. 53: Tapping the Aligning Tool 1

Lightly tap the aligning tool to make

sure it is centered and seated into the
pilot bearing.

18
Remove the guide studs and replace
them with bolts and lock washers.

19

W4001186
Fig. 55: Inserting Two Guide Studs
Insert two 7/16-14 UNC x 5 in. guide 7/16-14 UNC
studs into the two upper mounting x 5 in.
holes of the flywheel.

W4000393

Fig. 54: Tightening the Bolts

Starting with the lower left-hand bolt,

tighten the bolts in the crisscross se-
quence shown, to pull the clutch into
its proper position in the flywheel pilot.

CAUTION
Failure to tighten the bolts in this manner may cause W4001187

permanent damage to the clutch cover or create an Fig. 56: Rotate the Flywheel
out-of-balance condition.
Rotate the flywheel to level the two
guide studs.

46
Group 41
3 5
W4001188
Fig. 57: Inserting the Aligning Tool
Insert the aligning tool through the re-
lease bearing sleeve in the new clutch.
4
W4001189
Fig. 58: Rear Driven Disc on Aligning Tool
Put the rear driven disc on the aligning
tool with the side stamped ”PRES-
SURE PLATE” facing the pressure
plate.
Service Procedures
W4001190
Fig. 59: Placing the Plate in the Clutch Cover
Place the intermediate plate in the
clutch cover and align the driving lugs
of the plate with the slots provided.
The four positive separator pins in the
intermediate plate must be flush with
the cast lug on the pressure plate side.
W4001191
Fig. 60: Installing the Front Disc
Install the front disc on the aligning
tool with the side stamped
“FLYWHEEL” facing the engine.
47
Group 41
7 9
W4000390
Fig. 61: Flywheel
CAUTION
The side stamped “FLYWHEEL” must face the engine
and the side stamped “PRESSURE PLATE” must face
the transmission.
The relative position of the buttons on
the front and rear driven discs is not
important.
8 TM
Make sure that the Kwik-Adjust
mechanism is aligned with the opening
in the bell housing of the transmission.
48
Service Procedures
WARNING
Be careful to hold both driven disc and intermediate
disc on the aligning tool and the aligning tool in the
pressure plate. This assembly is very heavy, and can
slide off and drop, causing serious personal injury.
10
W4001192
Fig. 62: Positioning the Clutch Cover
Position the clutch over the guide 70 kg (150 lb)
studs and slide it forward until contact
is made with the flywheel surface.
Note: A 15-1/2 in. clutch assembly
weighs about 70 kg (150 lb) and a
hoist may be required to lift it into
place.
11
W4001193
Fig. 63: Starting the Mounting Bolts
Start six 7/16 in. x 2 1/4 in., Grade 5
or better, mounting bolts with lock
washers and tighten them finger-tight.
Group 41 Service Procedures

12 15
To achieve the final torque, progres- 61–68 Nm
sively tighten all bolts to 61–68 Nm (45–50 ft-lb)
(45–50 ft-lb). As the bolts are tight-
ened, the wooden spacers should fall
out. If they do not fall free, remove
them.

16
The aligning tool may have to be
tapped lightly with a mallet to remove
it.

17
W4001194

Fig. 64: Tapping the Aligning Tool

Lightly tap the aligning tool to make

sure it is centered and seated in the
pilot bearing.

13
Remove the guide studs and replace
them with bolts and lock washers.

14
W4000394

Fig. 66: Tapping Each Pin

Using a 1/4 in. diameter flat-nose drift,

lightly tap each of the four positive
separator pins toward the flywheel. Af-
ter tapping, the pins should be flush
against the flywheel.

W4001195

Fig. 65: Tightening the Bolts

Starting with the lower left-hand bolt,

tighten the bolts in the crisscross se-
quence shown, to pull the clutch into
its proper position in the flywheel pilot.

CAUTION
Failure to tighten the bolts in this manner may cause
permanent damage to the clutch cover or create an
out-of-balance condition.

49
Group 41 Service Procedures

4111-03-03-01 2

Clutch, Replacement
Spicer SAS Clutches

Before working on a vehicle, set the parking brakes,

place the transmission in neutral, disconnect the bat-
teries, and block the wheels. Failure to do so can
result in unexpected vehicle movement and can cause
serious personal injury or death.

For detailed illustration, see Fig. 17: Exploded View of

the Spicer SAS Clutch Assembly, page 23.

For lubrication information, see “Clutch, Lubrication”

page 65.
W4000255

Fig. 68: Inserting Wooden Blocks

Removal
Insert two 35 mm (1 1/2 in.) spacers 38 mm
1 between the flywheel ring and release (1 1/2 in.)
bearing housing. Spacers relieve the
internal spring load of the clutch as-
sembly.

W4000254

Fig. 67: Installing the Alignment Tool

Install the spline aligning tool through 1-3/4 in. x 10

the release bearing assembly and
driven disc into the pilot bearing. An
old transmission input shaft (1-3/4 in. x
10) may be used for this purpose.
W4000256

Fig. 69: Installing the Guide Pins

Loosen the clutch mounting bolts

around the flywheel in a criss-cross
pattern to prevent cocking and bend-
ing of bolts. Do not completely remove
the bolts.

Note: Because a 14–in. clutch weighs

about 35 kg (75 lb), the two guide
studs should be installed in top mount-
ing bolt holes to aid in removal of the
clutch.

50
Group 41 Service Procedures

4 Inspection
1
Inspect the flywheel. If it is heat
checked or warped, refer to the engine
manufacturer recommendations for
resurfacing or replacement.

W4000257
W4000246
Fig. 70: Removing the Clutch Cover Plate Fig. 72: Check Mating Surfaces
Remove mounting bolts and carefully
remove the clutch cover plate. 1 Flywheel housing
2 Transmission

Inspect mating faces of the transmis-

WARNING
Components are heavy and can be damaged or
cause serious injury if dropped! Be sure to hold the
alignment tool in the pilot bearing while removing the
pressure plate, as this prevents the driven disc from
falling out.
sion clutch housing and the engine
flywheel housing. Any appreciable
wear on either housing causes mis-
alignment.
3

W4000245

Fig. 73: Typical Wear Area

Most wear is found on the lower half of

faces between the 3– and 8-o’clock
positions. Replace the housing, if
worn.

W4000258
Fig. 71: Removing the Driven Disc and Alignment Tool
Remove the spline aligning tool and
driven disc.

51
Group 41 Service Procedures

4 6

W4000261

Fig. 75: Contacting Face of the Flywheel Housing

Move the gauge finger to contact the

face of the engine flywheel housing.
W4000260

Fig. 74: Securing Dial Indicator

7
Secure dial indicator to the engine fly- Rotate the flywheel and mark high and 0.02 mm
wheel or crankshaft, and place the low points. (0.008 in.)
gauge finger against the housing pilot.
Note: The total runout should not ex-
ceed 0.02 mm (0.008 in.).
5
Rotate the flywheel by hand, marking 0.02 mm
high and low points with chalk or (0.008 in.) 8
soapstone.

Note: The total indicated difference

between the high and low points must
not exceed 0.02 mm (0.008 in.).

W4000262

Fig. 76: Checking Flywheel Runout

Secure dial indicator to the engine fly-

wheel housing with the gauge finger
on face of the flywheel near the outer
edge.

52
Group 41 Service Procedures

9 Installation
Rotate the flywheel. 0.013 mm
(0.0005 in.) 1
Note: The maximum allowable runout
is 0.013 mm (0.0005 in.) per 25 mm (1
in.) of flywheel diameter. For example,
0.007 is allowable for a 350-mm (14–
in.) clutch.

10

W4000264

Fig. 78: Replacing the Pilot Bearing

Replace the pilot bearing. The bearing

must have a press fit only on the outer
race of the bearing when the tap is in-
stalled.

W4000263
2
Fig. 77: Checking Pilot Bearing Bore

Move gauge finger to contact the pilot

bearing-bore surface.

11
Rotate the flywheel. 0.127 mm
(0.005 in.)
Note: The maximum allowable runout
is 0.127 mm (0.005 in.).
Note: Exceeding these limits causes
misalignment. If not corrected, mis-
alignment causes premature wear of
the drivetrain components.

W4000265

Fig. 79: Installing the Two Guide Studs

Install the two guide studs, 3/8 in.–16 3/8 in.–16

UNC. Thread the studs 51 mm (2 in.) UNC
long at the 11- and 1-o’clock positions.

53
Group 41 Service Procedures

3 7

W4000266
Fig. 80: Installing the Driven Disc and Alignment Tool W4000268

Fig. 82: Torquing Sequence

Install the disc by inserting alignment
tool through the spline and into the pi- Install and hand-tighten capscrews 47–54 Nm
lot bearing. and lock washers according to the se- (35–40 ft-lb)
quence shown. Then tighten to 47–54 3/8 in.–16
Nm (35–40 ft-lb) torque. UNC
4
Make sure the side marked “pressure Note: Grade No. 5 (or better) cap-
plate side” faces the pressure plate. screws should be used (3/8 in.–16
UNC).
5
8
Replace the two guide studs with two
capscrews.

9
Tighten the capscrews to 47–54 Nm 47–54 Nm
(35–40 ft-lb) torque. (35–40 ft-lb)

W4000267
Fig. 81: Installing the Cover Plate
With alignment tool still in place, care-
fully slide the clutch assembly over the
alignment tool.

6
Align the lock strap where the access
hole is in bell housing.

54
Group 41 Service Procedures

10 Clutch Adjustment (Synchronized

Transmissions Only)
Note: The clutch assembly installed in this vehicle does
not require any internal adjustments.

W4000270

Fig. 83: Removing the Wooden Blocks

W4000243

The wooden blocks, installed earlier,
should have fallen out. If not, remove
them from between the release bear-
ing housing and flywheel ring.
11
Fig. 85: Throw-Out Bearing Preset Adjustments
1 24 mm (15/16 in.)
2 52.5 mm (2 1/16 in.)
All clutches, including a rebuilt exchange, are preset by
the manufacturer. On the early versions of the clutch as-
sembly, a label is placed to inform the technician that
this clutch is nonadjustable and that no attempt should
be made to adjust the clutch. Later versions will not have
adjustment access.

See “Slave Cylinder, Adjustment” page 59 for the appro-

priate slave cylinder adjustment procedures for models
with CAT Engine/Spicer Transmission/SAS Clutch or
CAT Engine/Fuller Transmission/SAS Clutch.

See “Clutch System, Bleeding” page 60 for the appropri-

ate procedure for clutch bleeding.

W4000269

Fig. 84: Removing Alignment Tool

Remove the alignment tool.

55
Group 41 Service Procedures

4111-05-02-01 2

Clutch, Adjustment

Before working on a vehicle, set the parking brakes,

place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.

For detailed illustrations, see:

TM

• Fig. 3: Exploded View of the 14 in. Easy-Pedal

clutch, page 14
• Fig. 4: Exploded
TM
View of the 15–1/2 in. W4000401
Easy-Pedal clutch, page 15 Fig. 86: Clutch Brake
• Fig. 17: Exploded View of the Spicer SAS Clutch
Assembly, page 23 Measure the clearance between the 12 mm (1/2
release bearing housing and clutch in.)
Explanation of Adjustments brake. If the clearance is less than 12
mm (1/2 in.), or greater than 15 mm
15 mm (9/16
in.)
Internal Clutch component wear is adjusted in- (9/16 in.), adjust the clutch as outlined
clutch ternally in the clutch through clockwise in the following steps.
adjustment rotation of the adjusting ring. This ad-
(normal justment moves the release bearing
service toward the transmission and re- 3
adjustments) establishes the 12 mm (1/2 in.) release To turn the adjusting ring, release the
travel and 6.4 mm (1/4 in.) free travel. clutch by depressing the clutch pedal
to the end of pedal travel.
Linkage Linkage adjustment should only be per-
adjustment formed in the following cases:

• Initial dealer preparation to set total

pedal stroke and yoke throw.

• To compensate for linkage wear,

clutch brake wear, transmission
bearing cap wear, or replacement
of relative clutch or linkage compo-
nents.

Internal Clutch Adjustment

Normal adjustment

Before working on a vehicle, set the parking brakes,

place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.

1
Remove the inspection cover at the
bottom of the clutch housing.

56
Group 41
4 5
W4000399
Fig. 87: Angle Spring
Adjust the clutch internally to get 12-
15 mm (1/2-9/16 in.) release. Turn the
adjusting ring as shown. The mea-
surement is taken with the pedal in the
UP position.
Angle Spring Clutches: Remove
lock strap and adjust with Spicer®
adjusting tool (Spicer® Tool Kit
CSK-1).
Easy Pedal
TM Clutches with Kwik-
Adjust : Insert a 19 mm (3/4 in.)
socket (12-point) or a 3/4 in. hole
and depress a square-headed
bolt to adjust
TM the clutch. The
Kwik-Adjust will re-engage at a
quarter of a turn. The flat on the
bolt head will align with the edge
of the bracket.
Service Procedures
TM W4000400
Fig. 88: Easy-Pedal
If the clearance between the release 12 mm (1/2
bearing housing and clutch brake is in.)
less than 12 mm (1/2 in.), rotate the 15 mm (9/16
adjusting ring counterclockwise to in.)
move the release bearing toward the
engine.
• If the clearance between the re-
lease bearing housing and clutch
brake is greater than 15 mm (9/16
in.), rotate the adjusting ring
clockwise to move the release
bearing toward the transmission.
• Reinstall the lock
TM
strap or be sure
the Kwik-Adjust is engaged in
the locked position, and release
the clutch pedal to engage the
clutch.
Free travel setting
CAUTION
The internal clutch adjustment must be completed be-
fore proceeding with the free travel setting.
Check clutch free travel (or clearance between the re-
lease yoke and release bearing as shown in ”Clutch
Brake,” Fig. 86: Clutch Brake, page 56). Set free travel
at 3 mm (1/8 in.) dimension by adjusting the external
linkage. This dimension correlates to a free pedal of ap-
proximately 38.1–50.8 mm (1 1/2–2 in.) in the cab.
Note: Consult OEM linkage adjustment procedures for
required free-pedal dimension and description of linkage
adjustment.
57
Group 41 Service Procedures

Clutch Brake Setting Adjustment for Synchronized

Transmissions Without a Clutch
Brake
Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.

1
Depress the clutch pedal. With the 25 mm
correct release travel and free travel (1 in.)
settings, the clutch brake ”squeeze”
should occur approximately 25 mm (1
in.) from the end of pedal stroke.

W4000403
2 Fig. 90: Distance Between the Clutch Cover and Housing

With the pedal depressed, turn the adjusting ring to ob-

tain approximately 15 mm (9/16 in.) between clutch
cover and release bearing housing. Check measurement
with the pedal up. See “Free travel setting” page 57.

Hydraulic Linkage
Refer to manufacturer specifications for proper adjust-
ment of the hydraulic system.

W4000402

Fig. 89: Distance of Pedal to Pedal Stroke

Depress the clutch pedal. The pedal 12–25 mm

should be 12–25 mm (1/2–1 in.) from (1/2–1 in.)
the end of the stroke at the beginning
of the clutch squeeze.

3
To check the distance of the pedal to 12–25 mm
the pedal stroke, insert a 0.010-in. (1/2–1 in.)
feeler gauge or business card between
the release bearing and clutch brake
(see Figure 52, “Clutch Brake,” Fig.
86: Clutch Brake, page 56). Depress
the clutch pedal and squeeze the
card. Let the pedal up slowly. Stop
when the card may be pulled out. The
pedal should be 12–25 mm (1/2–1 in.)
from the end of the pedal stroke.

4
Reinstall the inspection cover.

58
Group 41 Service Procedures

4134-05-02-01 4
Align the center line of the lever with
Slave Cylinder, Adjustment center line of the slave-cylinder clevis
Steps 1–7 cover slave cylinder adjustment for vehicles yoke.
with CAT engine, Spicer transmission and SAS clutch.

Steps 8–14 cover slave cylinder adjustment for vehicles 5

with CAT engine, Fuller transmission and SAS clutch. Push the cylinder piston in 15 mm
(19/32 in.) and adjust clevis yoke so
that the clevis yoke hole aligns with
hole in the lever.

Before working on a vehicle, set the parking brakes,

place the transmission in neutral, and block the 6
wheels. Failure to do so can result in unexpected Install the clevis pin and washer and
vehicle movement and can cause serious personal in- secure them with a cotter pin.
jury or death.
7
For detailed illustration, see Fig. 17: Exploded View of Tighten the locknut (2) against the
the Spicer SAS Clutch Assembly, page 23. yoke.

CAT Engine, Spicer Transmis-

sion, SAS Clutch
1
Position the release bearing fork so it
contacts the bearing pads. Turn the
shaft counterclockwise at the lever end
until contact is made.

W4000247
Fig. 91: Slave Cylinder Positioning

1 112 mm (4 13/32 in.)

2 Locknut
3 Flywheel housing
4 Transmission bell housing
5 Lever pinch bolt
6 Bleed nipple

Install the lever on the release shaft; 112 ± 2 mm

the distance between the flywheel (4 13/32 ±
housing/bell-housing joint seam and 3/32 in.)
the center of the lever clevis pin hole
(1) should be112 ± 2 mm (4 13/32 ±
3/32 in.).

3
Tighten the pinch bolt (5) to 54 Nm 54 Nm
(40 ft-lb) torque. (40 ft-lb)

59
Group 41 Service Procedures

CAT Engine, Fuller Transmission, 4139-05-02-01

SAS Clutch Clutch System, Bleeding
1
Position the release bearing fork in
contact with the bearing pads. Turn
shaft counterclockwise at the lever end
until contact is made. Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
2 vehicle movement and can cause serious personal in-
jury or death.

For detailed illustrations, see:

TM

• Fig. 3: Exploded View of the 14 in. Easy-Pedal

clutch, page 14
• Fig. 4: Exploded
TM
View of the 15–1/2 in.
Easy-Pedal clutch, page 15
• Fig. 17: Exploded View of the Spicer SAS Clutch
W4000248
Assembly, page 23
Fig. 92: Slave Cylinder Positioning Special tools: 9996928
1 96 mm (3 25/32 in.) 1
2 Locknut
3 Flywheel housing
4 Transmission bell housing
5 Lever pinch bolt
6 Bleed nipple

Install the lever on the release shaft; 96 ± 2 mm

the distance between the flywheel (3 25/32 ±
housing/bell-housing joint seam and 3/32 in.)
center of the lever clevis pin hole (1)
should be 96 ± 2 mm (3 25/32 ± 3/32
in.).

3
Tighten the pinch bolt to (5) 54 Nm 54 Nm
(40 ft-lb) torque. (40 ft-lb)

4
Align the center line of the lever with W4000252

the center line of the slave cylinder Fig. 93: Clutch Bleeding Setup
clevis.
1 Bleed nipple
2 C-clip
5 3 Slave cylinder
Push the cylinder piston in 15 mm 4 Bleed hose
(19/32 in.) and adjust the clevis yoke 5 Cigar plug
so that the clevis yoke hole aligns with 6 Fluid container
hole in the lever. 7 Mount bracket
8 ON/OFF switch
6 9 Pump
Install the clevis pin and washer and
Place pick-up tube in a 4 L (1 gal.) can
secure them with a cotter pin.
of hydraulic clutch fluid.

7
Tighten the locknut (2) against the 2
yoke. Plug the fluid pump wire into the dash-
board cigar-lighter receptacle.

60
Group 41
3 4311-02-01-01
Connect bleed hose to the slave-
cylinder bleed nipple.
4
Loosen bleed nipple about one turn
and use the metal C-clamp to lock
bleeder hose onto the nipple.
5
Remove the reservoir cap.
6
Using the ON/OFF switch on the wire,
turn switch to ON position to start the
pump. When the fluid has reached
FULL mark in the reservoir, turn pump
OFF.
Note: You must watch the fluid level in
reservoir to avoid it overspilling onto
the paintwork.
7 it into gear.
Close the bleeder nipple. Remove the
clamp and hose.
8 wear. If it is worn, replace it. Using a
Check the clutch operation.
9
Check the fluid level and top off as
necessary. Install the cap.
Service Procedures
Transmission, Installation
W4000161
Fig. 94: Correct transmission alignment
Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.
1
To reinstall the transmission, first shift
2
Inspect the transmission input shaft for
clean and dry cloth, wipe the shaft
clean.
3
Check for wear on the transmission
bearing caps. Refer to the transmis-
sion manufacturer’s Service Manual if
replacement is needed.
4
If a clutch brake is used, install it on
the input shaft.
5
Check for wear on the fingers of the
clutch release yoke. Also check the
cross shaft and the cross shaft bush-
ings. Replace them if necessary.
6
Check to be sure that neither cross
shaft protrudes through the release
fork, as this could cause side loading
of the release bearing.
61
Group 41 Service Procedures

7
CAUTION
The release fork fingers must not be elevated to the
straight-out position, as they could damage the clutch
cover when moving the transmission forward.

Rotate the release yoke so that it

clears and is rotated over the wear
pads of the release bearing as the
transmission is moved forward (see
Fig. 95: Rotating the release yoke,
page 62, Fig. 96: Rotating the release
yoke, page 62, and Fig. 97: Rotating
the release yoke, page 62).
W4000190

Fig. 95: Rotating the release yoke

8

CAUTION
Do not let the rear of the transmission drop or hang
unsupported in the splined hubs of the driven discs.
Failure to adequately support the transmission and
maintain alignment can damage the hubs, and can
result in poor clutch operation or clutch release prob-
lems.

Make sure that the transmission is

W4000191
Fig. 96: Rotating the release yoke
aligned with the engine when it is
raised into position. Be sure to support
the transmission and maintain align-
ment; taking proper precautions can
prevent bending and distortion of the
finely-tuned clutch discs, ensuring
trouble-free performance.

9
Move the transmission forward, but
never force the transmission into the
clutch or flywheel housing. If the trans-
mission does not enter freely,
investigate the cause and make ad-
justments until it does.

10
Mate the transmission with the engine
housing and install the mounting bolts.
Torque the bolts to the proper manu-
facturer’s specifications. Attach the
clutch release linkage.

W4000192
Fig. 97: Rotating the release yoke
11
With installation of the transmission
complete, adjustments may be made
to the clutch and, if necessary, to the
clutch linkage (see “Clutch, Adjust-
ment” page 56).

62
Group 41 System Check

System Check
Clutch, Lubrication
Spicer Easy Pedal Clutches
Clutch Release Bearings

WARNING
The release bearing housing has not been prepacked W4001196

with grease. It must be lubricated when the clutch is Fig. 98: Release Bearing Lubrication Point
installed in the vehicle or premature failure will occur.
Recommended Change Intervals
Note: For specific applications, contact your Spicer® rep-
resentative.

Use good-quality, lithium soap base, or equivalent, E.P.

Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.
Note: Clutches with permanently sealed release bear-
ings require no lubrication.
grease having an operating temperature range of 40–
 
160 C (100–325 F). In addition, the grease should meet
the N.L.G.I. Grades 1 or 2 specifications.1
Regular Service: Every 10,000 miles (16,000 km) or 1
month
Severe service highway2: Every 250 hours or 1 month

Lubricate clutches after adjustment and at regular main-

tenance intervals, or more often when service is extreme.

1
Do not mix lubricants with different bases without completely purging the system.
2
Any vehicle that operates off paved roads more than 10% of the time.
63
Group 41 System Check

Recommended Lubricants
Note: A high temperature lubricant should be used. Do
not use a chassis or all-purpose lubricant. Lubricate the
release bearing with a recommended lubricant as listed
below.

Supplier Product
American Oil Co. Amoco Lithium-M.P.
Grease
Atlantic Richfield Co. Arco M.P.
City Service Co. Citgo Premium Lithium
Grease #2 Fiske
Keystone Lubricating Co. #81 Light
Mobil Mobilgrease MP
Refining Co. Lubriplate 630-2
Shell Oil Co. Retinax A
Shell Oil Co. Alvania #2
Texaco Multifak #2
3
Chevron Oil Co. S.R.I. #2
Texaco3 Premium RB
3
Exxon Unirex N3

3
Approved for vendor prepack, other greases listed are for service only.
64
Group 41 System Check

Clutch, Lubrication Lubricate clutches after adjustment and at regular main-

tenance intervals, or more often when service is extreme.
Spicer SAS Clutches
Clutch Release Bearings
Vehicles equipped with the SAS clutch are supplied with
a greaseable release bearing.

WARNING
The release bearing housing has not been prepacked
with grease. It must be lubricated when the clutch is
installed in the vehicle or premature failure will occur.
W4000271

Fig. 99: Throw-Out Bearing Grease Nipple

Before working on a vehicle, set the parking brakes,

place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.

Recommended Lubricants
Note: A high-temperature lubricant should be used. Do
not use a chassis or all-purpose lubricant. Lubricate the
release bearing with a recommended lubricant as listed
below.

Supplier Product
American Oil Co. Amoco Lithium-MP
grease
Atlantic Richfield Co. Arco MP
Chevron Oil Co. Teknifak BRB-2 and SRI
No. 2
City Service Co. Citgo Premium Lithium
grease No. 2
Humble Oil Co. Lidox 2
Mobil Oil Mobil grease MP
Shell Oil Co. Alvania No. 2
Shell Oil Co. Retinax A
Texaco Multifax No. 2
Texaco Premium RB

65
66
 Operation Numbers

4111-03-03-01 Clutch, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 50

4111-05-02-01 Clutch, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4134-05-02-01 Slave Cylinder, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4139-05-02-01 Clutch System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4311-01-01-01 Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4311-02-01-01 Transmission, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
 Volvo Trucks North America, Inc.
P.O. Box 26115, Greensboro, NC 27402-6115
Volvo Trucks Canada, Ltd.
6490 Vipond Drive, Mississauga, Ontario L5T 1W8
http://www.volvotrucks.volvo.com

PV776-TSP137697 (1000) 01.00 © Volvo Trucks North America, Inc., 2000