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13
Clutch
Housing
Engine
Set
Screw
Set-Up
Tool
Taper
Lock
Bushing
13. Using the clutch set-up tool
(P/N 0555926), position
the clutch armature on the
engine shaft. Hold the tool
across the face of the clutch
housing so that the center,
recessed portion of the tool
straddles the clutch armature
assembly. Pull the clutch
armature assembly towards
the tool until the face of the
armature is against the tool.
14. While holding the clutch armature assembly against the tool,
use an 1/8” hex wrench and alternately tighten the set screws
into the taper lock bushing. Torque to 65–75 in/lbs.
15. Make sure the friction surface of the clutch armature is clean
and free from oil or grease.
Removing the clutch Rotor, clutch Field, and Drive Shaft
Assembly
1. Follow steps 1–7 in “Removing/Replacing the Clutch Armature
Assembly.”
2. Locate the clutch rotor assembly, which will be inside the
rear the gear housing. Note the locations of the three socket
screws and the two empty, threaded holes on the clutch rotor.
3. Using a 3/16” hex wrench, remove the three socket screws
and lock washers that secure the clutch rotor to the drive shaft
assembly.
4. Thread two of the socket screws into the empty, threaded
holes and tighten alternately. This will push the clutch rotor
away from the drive shaft assembly and pinion.
5. Using a Phillips screwdriver, remove the four screws that
secure the heat sink assembly to the housing. Carefully
remove the heat sink assembly from the housing.
6. Locate the two clutch field wires that pass from the gear
housing into the control housing through a hole in the back
of the control housing. Remember the wire connection
terminals on the relay assembly (label if necessary) and
disconnect the wires. Gently move the heat sink assembly
away from the housing and rest it on the work surface by the
control housing.
7. Locate the four pairs of set screws that secure the clutch field
to the gear housing. They are located on the exterior of the
gear housing at the 12, 3, 6, and 9 o’clock positions while
facing the clutch field end of the gear housing. Using an 1/8”
hex wrench, remove the setscrews. Remember the location
of the two clutch field wires with respect to the grommet and
EPC housing.
8. Carefully slide the clutch field out of the gear housing, keeping
the field square to the gear housing so it does not bind.
Clutch Rotor Socket Screw
Drive Shaft Assembly
Clutch Field Wires
Lock
Washer
Clutch
Rotor
Clutch
Field Assembly
Set Screw
Heat Sink Assembly Screw
Heat Sink Assembly
NOTE: To remove the drive shaft assembly, the pump
housing first must be removed from the gear
housing.
9. Using a Phillips screwdriver, remove the four front cover
screws. Remove the front cover.
10. Using a 1/4” hex wrench, remove the four socket screws that
secure the pump housing to the gear housing.
11. Slide the pump housing away from the gear housing.
12. Remove and clean the housing gasket. Replace if damaged.
13. Locate the drive shaft pinion that is protruding from the front
side of the gear housing. Remove the small snap ring that is
located on the drive shaft hub in front of the ball bearing that
is supporting the drive shaft.
14. From the opposite side of the gear housing (clutch side) slide
the drive shaft assembly out of the gear housing.
15. Inspect the grease seal located inside the bore from which
the drive shaft was removed. Replace if worn or damaged.
To remove the grease seal, use a flat blade screwdriver to
carefully pry the seal from the bore.
16. Clean the inside of the gear housing.
Front Cover
Grease Seal
Housing Gasket
Plug
Pump Housing Socket Screw
Small Snap Ring
Snap Ring
Bearing
Front Cover Screw
Installing the clutch Rotor Assembly, clutch Field and Drive Shaft
Assembly
1. If the drive shaft grease seal was removed, press a new seal
into the bore from which the old seal was removed.
2. From the clutch side of the gear housing, insert the drive shaft
assembly into the bore, through the grease seal, and through the
ball bearing on the gear side of the gear housing.
3. From the gear side of the gear housing, insert the snap ring
into the groove on the drive shaft hub in front of the ball
bearing.
4. Place the housing gasket over the gear housing dowel pins.
5. Carefully place the pump housing assembly in front of the
gear housing assembly, lining up the gear housing dowel pins
with their corresponding holes in the pump housing. Slide
the pump housing onto the gear housing until there is no gap
between the housings and gasket.
ImPORTANT: Do not force the pump housing and gear housing
together.
6. Locate the four socket screws and lock washers that secure
the pump housing to the gear housing.
7. Using a 1/4” hex wrench, snug and tighten the socket screws
in a crossing pattern. Torque to 200–230 in./lbs.
8. Line up the four holes around the outside of the clutch field
with the four set screw holes in the gear housing. The clutch
field wires should be at approximately the 1 or 2 o’clock
position.
9. Route the two clutch field wires through the hole and into the
control housing.
10. Carefully slide the clutch field into its bore in the gear housing
until it “bottoms out” within the housing. Do not pinch the
clutch field wires during installation.
11. Thread one of the pointed set screws into its hole. Using an
1/8” hex wrench, rotate the screw slowly until it contacts the
clutch field. Do not tighten the set screw. The tip of the set
screw should mate with the drill point hole in the field. Check
the clutch field for rotation. If it rotates within its bore, the set
screw is not seated within the drill point.
