Clutch Adjustment, Manually Adjusted Clutches

sd mm 25.05.001

Note: This procedure is only required for vehicles equipped with non-synchronized transmissions and manually adjusted clutches.

Release bearing travel is the clearance between the rear surface of the release bearing housing and the forward surface of the clutch brake disc. This distance must be maintained between 1/2 and 9/16 inch (12.7 and 14.3 mm).

  1. Remove the clutch inspection cover from the bell housing. See Fig..

    1. Clutch Inspection Cover

    Fig. 1, Remove the Clutch Inspection Cover

  2. Slide the clutch brake tight against the transmission input-shaft bearing cap.

    3. Important: Release bearing travel tool A02-12419-000 is available through the PDCs. The fork at one end of the tool has green tape on it, and has two 0.50-inch (12.7-mm) diameter tips; the fork at the other end has blue tape on it, and has 0.56-inch (14.3-mm) diameter tips. See Fig..

  3. Measure the release bearing travel. See Fig. for the correct dimension to measure. Using both ends of the release bearing travel tool, check this gap as follows:

    Position the tool so that the legs of the fork at the blue 0.56-inch (14.3-mm) end straddle the transmission input shaft. If the tool fits loosely, the gap is too wide and adjustment is needed. Go to the next step.

    If the blue 0.56-inch (14.3-mm) end can't be inserted in the gap, then try to insert the green 0.50-inch (12.7-mm) end.

    If the green end of the tool can't be inserted in the gap, adjustment is needed. Go to the next step.

    If the green end of the tool fits — snugly or loosely — then no adjustment is needed. Nothing more needs to be done. Install the clutch inspection cover.

    • Green End (0.50 inch or 12.7 mm)

    • Blue End (0.56 inch or 14.3 mm)

    Fig. 2, Release Bearing Travel Tool A02-12419-000

    • Clearance between release bearing housing and clutch brake must be 1/2 to 9/16 inch (12.7 to 14.3 mm).

    1. Release Bearing Housing

    2. Clutch Brake

    Fig. 3, Release Bearing Travel Measurement

  4. Release the clutch by depressing the pedal. Block the pedal in the released position, or have someone assist you by holding the pedal down during the adjustment procedure.

    5. Note: An open-end wrench is not recommended for the following step.

  5. Adjust the clutch, using a 5/8-inch box-end or socket wrench on the adjustment bolt. See Fig..

    Fig. 4, Manual Adjustment, Easy-Pedal Clutch (shown with bell housing removed)

    1. Insert the 5/8-inch box-end or socket wrench through the inspection cover opening.
    2. To begin the adjustment, release the adjustment bolt by pressing down on the bolt head.

      3. Note: On Easy-Pedal 2000 clutches, each complete turn of the adjustment bolt represents about 0.125 inch (3 mm) of release bearing movement.

      Normal wear increases the gap between the release bearing and the transmission.

    3. To decrease the gap : If clearance between the release bearing housing and the clutch brake is more than 9/16 inch (14.3 mm), turn the adjustment bolt clockwise (the release bearing moves toward the transmission).
      To increase the gap : If clearance between the release bearing housing and the clutch brake is less than 1/2 inch (12.7 mm), turn the adjustment bolt counterclockwise (the release bearing moves toward the engine).
    4. When the adjustment is complete, make sure the adjustment bolt is locked (pulled up flush with the mounting bolts).
  6. After adjusting, release the pedal and check the clearance between the release bearing housing and the clutch brake. When the adjustment is correct, the green end of the tool should go in and the blue should not (clearance of 1/2 to 9/16 inch, or 12.7 to 14.3 mm).
  7. Install the clutch inspection cover.
Note:
Parent topic: Clutch
Document Number: 0000119716
Manual Publication Date: 2024-05-23
Topic Publication Date: 2024-10-30