For 1990-2009 cars

## Clutch Assembly Adjustment Resetting procedure in vehicle

Important: Reset the clutch if one or more of the following conditions occurs:

• | The clutch was removed for engine repair.

• | The clutch was unbolted from the flywheel without first installing the shipping/resetting bolts.

• | The clutch was unbolted from the flywheel in order to realign the discs during clutch installation.

• | The clutch pedal was depressed after clutch installation and one of the following conditions occurs:

- | 101-127 mm (4-5 in) of free pedal is present in the clutch pedal.

- | The release bearing moved near the transmission.

- | The clutch tab moved halfway towards the "REPLACE" position.

1. Depress and hold the clutch pedal completely down.

Important: The wear indicating tab should be moved with finger pressure. Do not force the tab to move by striking or prying it.

2. Move the wear indicating tab to the "NEW" (1) position.
3. Release the clutch pedal. The wear indicating tab is now reset.

Important: It will be necessary to rotate the flywheel in order to gain access to all 4 clutch pressure plate shipping bolts.

4. Using the inspection window in the transmission bell housing to gain access to the pressure plate, install four 3/8 x 16 x 1 - 1/4 inch UNC hex head bolts (the same bolts used to cage the pressure plate when the clutch was shipped). Turn the bolts until the pressure plate is fully retracted.
5. Inspect the gap under each tamper proof plate spacer bolt with the pedal depressed.

Specification

• | Single Plate Clutch - 0.9 mm (0.035 in)

• | Two Plate Clutch - 1.4 mm (0.055 in)

6. Remove the shipping bolts.
7. Ensure that there is no gap between the plate spacer roll pin and the tamper proof plate spacer bolt when the pedal is released.
8. The plate spacer pins are now reset.
9. Stroke the clutch pedal a minimum of five times to allow the clutch to automatically reposition the bearing.

## Clutch Assembly Adjustment Resetting procedure out of vehicle

Important: Use this procedure if transmission and clutch were removed without following the correct removal procedure.

1. Support the clutch in an arbor press with the bearing facing down.
2. Allow an additional 25.4 mm (1 in) space for the bearing to move down, and allow access to install the four shipping bolts.

Important: Do not apply excess force on the retainer because the Solo's internal stops can deform the clutch's stamped cover. Eaton recommends using a manually operated arbor press, not a hydraulic press, to avoid distortion of the clutch's stamped cover.

3. Center the ram and press downward on the retainer until it comes to a stop. Lock the ram in position.
4. Remove the 4 shipping bolts, if they have been installed.
5. Raise the ram approximately 2.54 mm (1 in).

Important: Do not apply excess force on the retainer because the Solo's internal stops can deform the clutch's stamped cover. Eaton recommends using a manually operated arbor press, not a hydraulic press, to avoid distortion of the clutch's stamped cover.

6. Press down on the retainer until it comes to a stop. Lock the ram in this position.
7. Using finger pressure, slide the clutch wear indicating tab to the left until it is at the "NEW" position (1), and hold it in this position with a magnet.

• | Using four 3/8 x 16 x 1 1/4 inch UNC hex head machine screws.

• | Install the machine screws into the 4 cover holes and turn them finger tight.

| Important: You may need to temporarily install slightly longer bolts to allow access of the 1 1/4 in shipping bolts.

• | Progressively tighten the four shipping bolts in a crisscross pattern until the face of the pressure plate (2) is below the mounting surface (3).

Specification
Pressure plate below mounting surface - 13.3 mm (0.525 in).

• | This step will reset the pressure plate spacers and allow the clutch to release after reinstallation.

• | Install the clutch. Refer to Clutch Assembly Replacement .

## Clutch Assembly Adjustment Internal

1. Disconnect the clutch linkage.
2. Remove the inspection plate bolts, washers, and plate.
3. Measure the distance between the clutch cover and the release bearing.
4. For synchronized transmissions, regular production options (RPOs) MK0/ML0/MM0/MPU/MW0, the specifications should be:

Specification
Clutch cover to release bearing - 17.8 mm (0.70 in)

5. For non-synchronized transmissions, RPOs MPB/MPE/MPH/MUT, the specifications should be:

Specification
Clutch cover to release bearing - 18.6 mm (0.73 in)

6. Depress the clutch pedal to move the adjusting ring in order to adjust the bearing position.
7. Insert a 12-point socket or a box-end wrench through the inspection hole and depress the square headed bolt to adjust the clutch.
8. The kwik-adjust will re-engage at a quarter of a turn. The flat on the bolt head will align with the flat edge of the bracket.

• | To increase the release bearing dimension, rotate the adjusting ring clockwise

• | To decrease the release bearing dimension, rotate the adjusting ring counterclockwise

9. After the correct bearing position is achieved, ensure that the kwik-adjust is engaged in the locked position and release the clutch pedal to engine the clutch.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

10. Install the inspection plate, bolts, and washers.

Tighten
Tighten the inspection cover bolts to 12 N·m (106 lb in).

11. Connect the clutch linkage.