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Solo AdvantageSelf-Adjusting ClutchesInstall TransmissionCheck Transmission for WearReplace any worn components.Transmission BearingRetainer CapA worn/rough bearingretainer cap may causethe clutch brake to wearprematurely.Cross Shaft and BushingsExcessive wear at these points can causeside loading on the sleeve bushing,bushing failures and yoke bridge contactwith the clutch when the pedal is down.Input Shaft SplinesAny wear on the splines willprevent the driven discs fromsliding freely, causing poorclutch release (clutch drag).Slide discs full length of shaft tocheck for twisted shaft splines.IMPORTANTInstallDo not add lube (never seizeor grease) to the input shaftsplines. The discs must befree to move.Input Shaft SpigotWear will not provide properinterface with the inner race ofthe pilot bearing. This canresult in damage to the clutchor the pilot bearing.Release YokeWorn fingers cancause bushing wearand yoke interferencewhen the pedal is down.Clutch BrakeReplace.Input ShaftWear (roughness) canreduce sleeve bushing lifeand cause it to come out.Measure Input ShaftLength should be 8.657" (219.89 mm) nominal, and notgreater than 8.71" (221.23 mm). Ref. 1990 SAEhandbook 4:36.106. Replace transmission bearingretainer cap if length is greater than 8.71" (219.89 mm).CAUTIONDo not excessively force the transmissioninto the clutch assembly or enginehousing. This will cause damage to thesplines of the rear disc hub that is notwarrantable. If the discs do not slide freelyin the input shaft, investigate the cause ofthe problem and make any necessarychanges. If the discs do not slide freely, theclutch will not release and the transmissionwill grind going into gear.Do not let the transmission drop or hangunsupported in the driven discs. This canbend the discs and the clutch will not releasecausing damage that is not warrantable.Do not use the cross-shaft release lever (ora pipe over it) to pull the transmission intoits final position. Pulling the bearing too farduring installation can cause an overstrokecausing the release bearing to move closerto the transmission (less than 0.490") withthis condition. Follow the Out of VehicleResetting Procedure on page 1.Note: Adjust the linkage until pushingthe pedal down moves the bearingagainst the clutch brake. Let up on thepedal and measure the distancebetween the bearing and clutch brake(distance should be 0.490"-0.560").5

Solo AdvantageSelf-Adjusting ClutchesFasten Transmission to Flywheel Housing1 Put transmission in gear.2 Make sure that the yokeMake sure new clutchbrake has been installed.fingers remain in the upposition until they are overthe release bearing housing.3 Position transmission soit is square to andaligned with engine.4 Mesh splines by movingCAUTIONDo not pull on release arm to installtransmission. This will cause theclutch to over adjust.Do not force transmission againstclutch with yoke fingers in the UPposition. This will break the castwebbing of the clutch causingdamage that is not warrantable.Do not use excessive force. If itdoes not enter freely, investigatethe cause of problem and makeany necessary changes.transmission forward androtating the output shaft.IMPORTANTDo not add lube (never seize orgrease) to the input shaft splines.The discs must be free to move.5 Install mounting bolts andtorque to OEM specs. Ifinstalling Solo Advantageclutch, proceed to Step 6.WARNINGDo not let the transmissiondrop or hang unsupported inthe driven discs. This can causethe discs to become distortedand the clutch to not release.6 Install hand hold coverA-8173 with grommetpositioned toward rear ofhand hold opening in theclutch housing. Secure thehand hole cover with two5/16" x 18 x 1/2" long bolts.7 Insert plug into hole in the upperleft side of the clutch housingwhere the horizontal lube hoseis utilized. (Image not shown)Note: If the lube hose assemblyshould need servicing it can bereplaced without removal of thetransmission.6

Solo AdvantageSelf-Adjusting ClutchesSet-upAdjust Clutch Linkage1 Hydraulic Linkages:Skip to Step 2.Mechanical Linkages Only:Adjust the clutch linkage until theyoke fingers contact the releasebearing (zero free-play in cab).0.00"2 Press the pedal to thefloor up to 5 times, this: Moves release bearingslightly closer to thetransmission Gains free-play in 0"-0.560"(12.70-14.22 mm)3 With the pedal up, measure thedistance between the release bearingand the clutch brake. The correctdistance should be 0.490"-0.560"(12.70-14.22 mm): If the distance is more the 0.560"(14.22 mm), return to Step 1 andreadjust the clutch linkage. If the distance is less the 0.490"(12.70 mm), see Solo AdvantageHeavy-Duty 15.5" ClutchTroubleshooting. Go to page 10.7

Solo AdvantageSelf-Adjusting ClutchesVerify Clutch Brake SqueezeWARNINGUse a gauge long enough to keephands away from moving parts.4 Have an assistant insert 0.010"(0.25 mm) feeler gauge betweenthe release bearing and theclutch brake.Press the pedal down to the floorto reclamp the gauge: If the gauge does not clamp,readjust the truck linkage andmove yoke fingers closer tothe bearing.YokeFinger5 Slowly let up on the pedal andmeasure the pedal position at themoment the gauge can be removed: If pedal is more than 1" (25.4 mm)from the floor, readjust the trucklinkage to move the yoke fingersfurther from the release bearing.Return to Step 4.Less than 1"(25.4 mm)Verify Free-Play6 Verify there is free-play in the cab. If not, thetruck linkage is not providing enough stroke,consult OEM manual for free-play dimension.For Solo clutches, proceed to Step 8. For SoloAdvantage clutches, proceed to Step 9.IMPORTANTDO NOT RESET THE CLUTCH. Do not changefree-play by readjusting the clutch linkage.8ReleaseBearingClutchBrake

Solo AdvantageSelf-Adjusting ClutchesLubricateNote: All clutches use a Lithiumcomplex grease with a minimumof 325 F (163 C) operating rangemeeting NLGI grade 2 or 3 specs.For additional lubricationinformation, see TCMT0021.CAUTIONFailure to properly lubricate thebearing/bushing will result inbearing and sleeve failures.ZerkInputShaftSet-up7 Apply ample grease that is visiblyexiting the opening and contactsthe transmission shaft. This willlube the clutch brake and bushingwhen the pedal is pressed.82 Apply grease to input shaftand yoke fingers.9 Apply grease to the crossshaft bushings and linkagepivot points.IMPORTANTInput ShaftDo not add lube (never seize orgrease) to the input shaft splines.The disc must be free to move.9

Solo AdvantageSelf-Adjusting ClutchesTroubleshooting for Solo Advantage Heavy-Duty 15.5" ClutchesSymptom-Driven DiagnosticsIf clutch is out of vehicle, go to Outof-Vehicle Resetting Procedure on page 16.Based on your symptom, the chart willdirect you to the correct solution.Too Much Free Pedal:Not Enough Free Pedal:NotenoughtravelToomuchtravelPedal travels too far before engagingthe clutch. Clutch does not disengage.Go to page 11.Too Much Clutch Brake:Pedal travels too little beforeengaging the clutch.Go to page 12.No Clutch Brake:Too muchbrake squeezeGo to page 11.10Not enoughbrake squeezeGo to page 12.

Solo AdvantageSelf-Adjusting ClutchesToo muchtravelTroubleshootingToo Much Free Pedal or Too Much Clutch BrakeToo muchbrake squeezeNote: Before measuring the distancebetween the release bearing andclutch brake depress clutch pedal toremove free pedal in the cab.ReleaseBearing1 Measure distancebetween release bearingand clutch brake.ClutchBrake2 Use chart to findsolution.MeasurementIf distance is correct0.490"-0.560"(12.45 - 14.22 mm)If distance isLess than 0.490"(12.45 mm)StatusClutch isset up correctlySolutionProblem exists with truck linkage. Repairaccording to OEM specifications.Hydraulic Linkage: Go to page 49.Clutch is notset up correctlyIf clutch was factory installed and was neverremoved or if clutch was removed from engineand reinstalled, go to page 13.If new/reman clutch was installed and it neveroperated properly, check wear tab position.If tab at GOOD position: Disc is installed incorrectlyGo to page 3, Step 4 and 5. Damper is too large for the flywheel openingGo to page 3, Step 1.If tab not at GOOD position, the bearing mayhave been pulled during installation, causingan overadjust.Go to page 16.11

Solo AdvantageSelf-Adjusting ClutchesNot Enough Free Pedal or No Clutch BrakeToo littletravelNot enoughbrake squeezeNote: Before measuring the distancebetween the release bearing andclutch brake depress clutch pedal toremove free pedal in the cab.ReleaseBearing1 Measure distancebetween release bearingand clutch brake.ClutchBrake2 Use chart to findsolution.MeasurementIf distance is correct0.490"-0.560"(12.45 - 14.22 mm)If distance isMore than 0.560"(14.22 mm)StatusClutch isset up correctlySolutionProblem exists with truck linkage.Repair according to OEM specifications.Hydraulic Linkage: Go to page 49.Clutch is notset up correctlyIf clutch was factory installedand was never removed,Mechanical Linkage: Go to page 14.Hydraulic Linkage: Go to page 49.If clutch was removed fromengine and reinstalled,(Setup) Go to page 7.If new/reman clutch was installedand it never operated properly,(Setup) Go to page 7.12

Solo AdvantageSelf-Adjusting ClutchesResetting ProceduresIn-Vehicle Reset Procedure1 Have assistant holdclutch pedal down.Hold2 While pedal is held down,Resettingmove wear tab to the left(GOOD) position.GOODNote: If the cam does notmove, loosen transmission andinstall 1/2" spacers between theclutch housing and enginehousing to increase stroke.6 Push pedal down andsqueeze clutch brake5 times to repositionbearing.5X With spacers in place, followSteps 1-3 in this procedure. Remove spacers and torquetransmission mounting bolts. Continue process starting atStep 4.5 Removeshipping bolts.3 Let up on pedal. DO NOTpush pedal down again orwear tab will return to thewrong position.BeforeAfter4 Install and tighten 4shipping bolts (7/16" x 14x 1-3/4 UNC) until theyquit turning.Note: This will remove thegap between the sleeveand the pin.ShippingGapBoltSleevePinNo gap betweensleeve and pin13

Solo AdvantageSelf-Adjusting ClutchesIn-Vehicle Resetting Procedure Using the Solo Advantage Clutch Reset ToolTool Part Code:RR1005CLK-Line 1-800-824-55461Determine if the release bearing travel iscorrect. Measure the distance between theclutch brake and the release bearing withthe clutch pedal up. If the measurement isbetween 0.490" and 0.590", the Solo hasset itself correctly.Note: Yoke gap only applies to mechanicallinkage. Most hydraulic linkages operatewithout yoke gap.2ReleaseBearingIf the release bearing travel is less than 0.490"the Solo must be reset. A common cause of thisis the transmission was pulled in with the releasearm during clutch installation.ClutchBrake34Rotate the engine so that the cam tab canbe reached through the transmissioninspection opening.Push the clutch pedal to the floor. While the clutch pedalis pushed to the floor have someone push the cam tab tothe new position using finger pressure or the Solo tool.Once the cam tab is pushed to the new position you canrelease the clutch pedal.Note: If the cam tab does not move, there is not enoughrelease bearing travel to allow the cams to separate. Inthis case, loosen the transmission and install 1/2"spacers between the flywheel housing and bell housing.With the spacers in place push the clutch pedal to thefloor while someone pushes the cam tab to the newposition. Once the tab is in the new position release theclutch pedal and remove the spacers. Torque thetransmission mounting bolts.14Measure the releasebearing travelREPLACE

Solo AdvantageSelf-Adjusting Clutches5Install (4) shipping bolts and progressively tightenby hand until they bottom out. Rotate the engine toaccess all 4 bolts: 15 1/2" Solo use 7/16 x 14 UNC x 1 3/4" Stamped 14" Solo use 3/8 x 16 UNC x 1 1/4"Note: This will reset the pressure plate separatorpins and allow the clutch to release after installation.Remove the (4) shipping bolts. The release bearing andsleeve will move forward towards the engine when thebolts are removed. The Solo is now in the new position.7With the free pedal removed push the clutch pedal downat least 5 times. Make sure the clutch release bearingcontacts the clutch brake.Shipping BoltWhile you engage and release the clutch the cab free pedalwill increase. This indicates the Solo is adjusting to theenvironment.8Measure the distance betweenthe clutch brake and the releasebearing. It should be between0.490" and 0.590".9Resetting6Tamper-ProofBoltShipping BoltsIf the release bearing travel is stillgreater than 0.590" between theclutch brake and the releasebearing, repeat Steps 7 and 8.10Adjust the clutch linkage toachieve 1/8" clearance betweenthe release yoke and therelease bearing. Verify properclutch brake squeeze.Verify Clutch Brake SqueezeWARNINGUse a gauge long enough to keephands away from moving parts.YokeFinger1 Have an assistant insert 0.010" (0.25 mm)feeler gauge between the releasebearing and the clutch brake.Press the pedal down to the floor toclamp the gauge: If the gauge does not clamp, readjustthe truck linkage and move the yokefinger closer to the bearing.ReleaseBearingClutchBrake2 Slowly let up on the pedal andmeasure the pedal position at themoment the gauge can be removed: If pedal is more than 1" (25.4 mm)from the floor, readjust the trucklinkage to move the yoke fingersfurther from the release bearing.Repeat Step 1.Less than 1"( 25.4 mm)15

Solo AdvantageSelf-Adjusting ClutchesOut-of-Vehicle Reset Procedure for Heavy-Duty ECA or Solo Advantage Clutches1 Remove the 4 shipping2 Support the clutch in an arbor pressbolts if they have beeninstalled.3 Center the ram andwith the bearing facing down.press downward on theretainer until it comes toa stop. Lock the ram inposition.Note: Make sure there is atleast 1" of space to allowthe bearing to movedown and to provideaccess to theshipping bolts.4 Slide the wear indicator tab tothe “GOOD” position and holdit in place with a magnet5 Install 4 shipping bolts (7/16" x 14 x1-3/4" UNC, hex head). Progressivelytighten (no air wrenches) the 4shipping bolts (crisscross pattern)until the face of the pressure plate is1.75"-1.78" (44.4-45.2 mm) belowthe mounting surface.Shipping Bolts1.75"-1.78"(44.4-45.2 mm)6 Reinstall the clutch usingthe original installationinstructions.16Note: This important step will reset thepressure plate separator pins and allowthe clutch to release after reinstallation.

Easy Pedal AdvantageManual Adjust ClutchesInstall Easy Pedal Advantage and ValueClutchMeasure Engine Flywheel Housing and FlywheelEngine flywheel housing and flywheel must meet these specifications or may result in a premature clutch failure. Remove andreplace old pilot bearing per engine manufacturer instructions. All gauge contact surfaces must be clean and dry. Clean flywheelsurfaces of all grease, oil, and rust preventatives. Failure to perform this function can affect the performance of the clutch.Use a dial indicator and check the following:Flywheel Face Runout1 Secure dial indicatorbase to flywheelhousing face.Pilot Bearing Bore Runout2 Put gauge finger incontact with flywheelface near the outer edge.1 Secure dial3 Rotate flywheel onerevolution. Maximumrunout is 0.008" (0.20 mm).revolution. Maximumrunout is 0.005" (0.13 mm).Flywheel Housing Face RunoutFlywheel Housing I.D. Runoutbase to crankshaft.so that it contactspilot bearing bore.2 Put gauge finger1 Secure dial indicatoragainst flywheelhousing pilot I.D.base to flywheel nearthe outer edge.3 Rotate flywheel onerevolution. Maximumrunout is 0.008" (0.20 mm).2 Put gauge finger in3 Rotate flywheel onecontact with face offlywheel housing.revolution.Maximum runout is0.008" (0.20 mm).17Install3 Rotate flywheel one1 Secure dial indicator2 Position gauge fingerindicator baseto flywheelhousing face.

Easy Pedal AdvantageManual Adjust ClutchesInstall Clutch to FlywheelInstall 15.5" Clutch to Flywheel (Easy Pedal Shown)WARNINGIMPORTANTUse the Eaton Clutch Selector Guide (CLSL1511)to make sure you have the right clutch.An assembled clutch weighs about 150 lbs (68 kg).Avoid the risk of injury. Use proper equipmentwhen lifting a clutch.Note: When installing clutch to flywheel, positionthe adjuster at the bottom of flywheel to easefuture clutch servicing.Note: Easy Pedal or manual adjust clutchassemblies not recommended for use withhydraulic release systems.1 Measure the flywheel bore.Use the Eaton ClutchSelector Guide to verify thatthe damper will fit into theflywheel bore.6 Install two 7/16" x 14UNC x 5" studs into uppermounting holes. Installassembled clutch.7.0" (8-spring)8.5" (10-spring)10.0" (7-spring and Mack 9-spring)Note: Mack 9-spring for Mack and Volvoengines 2007 and newer only.5 Install second disc onto aligningtool. Follow the orientationinstructions on the disc.4 Install intermediate plate into slotson the clutch cover. Flywheel Sidemust face the flywheel.3 Install disc onto aligning tool.Follow the orientationinstructions on the disc.2 Insert aligning toolthrough bearing.64827 Install lock washers and mountingTOPRES SNBOLTRTU1DE75bolts (7/16" x 14 UNC x 2-1/4"grade 5) finger tight. Replacestuds with lock washers and bolts.39 Verify bearing position is 3/8"–5/8"8 Progressively tighten mounting bolts(9.5–15.9 mm) from cover.10 Remove the aligning tool. Be sureshipping blocks are removed.BOLTES SPRDE18RNnose punch to lightly tap the fourseparator plate pins toward the flywheel(New EP Only). Reman and Value clutchesdo not have pins. Only part of the pinshould be visible.TOTU11 Use a six ounce hammer and a 1/4" flatin a crisscross pattern starting with thelower left bolt (1, 2, 3, 4, 5, 6, 7, 8).Torque to 40-50 lb-ft (54-68 N m).Failure to do this could result inimproper piloting of the clutchand cause clutch damage.Pin

Easy Pedal AdvantageManual Adjust ClutchesInstall 14" Clutch to Flywheel1 Ensure the correct flywheeldepth is 2-15/16".2 Put front disc into flywheel.Flywheel side must be towardengine. Use new slots to putintermediate plate on pins.Super-duty clutch only:3 Install three equally4 Turn intermediate plate left. Usespaced anti-rattlesprings.0.006" feeler gauge to check leftpin clearance on all 6 drive pins.Note: Checkorientation onanti-rattle springsbefore installing.Note: Remove two set screws.Straighten pins to increaseclearance and reinstall setscrews. Do not file slots.6 Install disc into7 Install9 Insert aligningtool throughdiscs.disc ontoflywheel. Followthe orientationinstructions onthe disc.intermediateplate ontodrive pins.studs into uppermounting holes.Install8 Install secondflywheel. Followthe orientationinstructions onthe disc.5 Install two 3/8" x 2-1/2"10 Slide cover o

The major cause of clutch failure is excessive heat. Excessive heat generated between the flywheel, driven discs, intermedi- . lined in the Failure Analysis Guide. When disassembling various assemblies, lay all parts on a . Use the Eaton Clutch Selector Guide to verify that the damper will fit into the flywheel bore. 7.0" (8-spring) .