D6D TRACTOR POWER TRAIN – Flywheel Clutch (Direct Drive and Special Application)

Remove And Install Flywheel Clutch (Direct Drive And Special Application)

Start by: (for machines with a cab)

a. tilt cab back*

b. remove universal joint (direct drive and special application)

c. remove dash

d. remove hydraulic oil tank

e. remove crankcase guard

Start by: (for machines without a cab)

a. remove Roll-Over Protective Structure*

b. remove universal joint (direct drive and special application)

c. remove dash

d. remove hydraulic oil tank

e. remove crankcase guard


*

1. Drain the oil from the flywheel clutch.

2. Release the flywheel clutch before it is removed.


NOTICE

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.


3. Remove tube assembly (1), hose assembly (2) and tube assembly (3).

4. Disconnect rod assembly (5) from lever (6).

5. Remove the cotter pin and pin (7). Loosen the bolt and nut (4) and remove lever (6).

6. Remove clip (8).

7. Disconnect wires (10).

8. Remove interlock linkage (9).

9. Remove cover (11) and the gasket.

10. Remove eight bolts (12) and the washers.

NOTE: The flywheel must be turned for removal of all eight bolts.

11. Fasten tool (A) to the flywheel clutch housing as shown. Fasten a hoist to tool (A).

12. Remove nuts (13) and the washers.

13. Install a safety wire (14) around the clutch group and the flywheel clutch case as shown. The wire will hold the clutch group in position on the shaft when the unit is removed from the machine.

14. Install two 3/8″-16 NC forcing screws in the flywheel clutch case. Tighten the screws evenly until a separation of the flywheel clutch is made from the flywheel housing.

NOTE: If necessary, install two 1/2″-13 NC forcing screws in the adjustment ring to make a separation of the ring from the flywheel.

15. Remove flywheel clutch (15). The weight of the flywheel clutch is 250 lb (113 kg). Remove the gasket from the flywheel housing.

16. Remove two disc assemblies (16) and the one plate.

17. Remove the three locks, bolts and retainers that hold hub (17) to the flywheel. Remove the hub.

18. Remove ring (20), the inner race, roller assembly (19) and ring (18).

19. Remove the outer race from the flywheel with tooling (B).

NOTE: The following steps are for the installation of the flywheel clutch (direct drive and special application).

20. Lower the temperature of the outer race and install it in the flywheel with tooling (A) until it makes contact with the bottom of the counterbore in the flywheel.

21. Put ring (8) in position on the hub as shown. Heat inner race and roller assembly (9) to a maximum temperature of 275°F (135°C) and install it on the hub until it makes contact with the shoulder on the hub. Install the spiral ring in the groove on the hub.

22. Put the hub in position on the flywheel as shown. Install the three retainers bolts and locks that hold it.

23. Make sure the two disc assemblies and one plate are clean before they are installed in the flywheel.

24. Install two disc assemblies (16) and the plate. Start with a disc assembly.

25. Make sure the clutch group is fastened to the flywheel clutch case before the unit is installed in the machine.

26. Fasten tool (A) and a hoist to the flywheel clutch.

27. Put a new gasket in position on the flywheel housing. Put flywheel clutch (15) in position on the flywheel housing. Make sure the bolt holes in the adjustment ring of the flywheel clutch are in alignment with the bolt holes in the flywheel.

28. Install twelve washers and nuts (13) that hold the flywheel clutch to the flywheel housing. Remove safety wire (14).

29. Install eight bolts (12) that hold the adjustment ring to the flywheel. The flywheel must be turned to install all the bolts.

30. Install the gasket and cover (11).

31. Install interlock linkage (9).

32. Fasten clip (8).

33. Connect wires (10).

34. Put lever (4) in position on the shaft in the flywheel clutch as shown. Connect rod assemblies (6) and (5). Tighten the bolt and nut that holds the lever to the shaft.

35. Install tube assemblies (1) and (3) and hose assembly (2).

36. Fill the flywheel clutch with oil to the correct level. See Lubrication and Maintenance Guide.

37. If necessary make adjustments to the flywheel clutch, flywheel clutch control linkage, flywheel clutch brake and the interlock linkage. See Adjustment of Flywheel Clutch, Adjustment of Flywheel Clutch Control Linkage, Adjustment of Flywheel Interlock Linkage in Specifications.

End By: (for machines without a cab)

a. install crankcase guard.

b. install hydraulic oil tank.

c. install dash.

d. install universal joint (direct drive and special application).

e. install Roll-Over Protective Structure*.

End By: (for machines with a cab)

a. install crankcase guard.

b. install hydraulic oil tank.

c. install dash.

d. install universal joint (direct drive and special application).

e. tilt cab forward*.


*

Disassemble Flywheel Clutch (Direct Drive and Special Application)

Start By:

a. remove flywheel clutch.

1. Put the flywheel clutch on wood blocks as shown. Remove the wire that holds the clutch group in position.

2. Remove flywheel clutch oil pump (1).

3. Remove flywheel clutch brake (3).

4. Remove shaft (2) and the drum from the flywheel clutch.

5. Remove four bolts (4) and drum (5).

6. Remove bearing race (6) with tooling (A).

7. Install two 3/8″-16 NC forged eyebolts in the flywheel clutch case.

8. Fasten a hoist to the flywheel clutch case. Weight of the flywheel clutch case is 100 lb. (45 kg). Remove the flywheel clutch case (7).

9. Remove bolts (8) and lever (9).

10. Use a soft face hammer to remove the cage (10) from the flywheel clutch case.

11. Remove seal (11).

12. Remove the retainer that holds the bearing in position in the cage.

13. Remove bearing (12). Remove the O-ring seal from the cage. Check the condition of the seal. If the seal has damage, use a new part for replacement.

14. Remove two bolts (13).

15. Pull the yoke up as shown. Remove shaft (14) and key (15). Pull the shaft all of the way out of the flywheel clutch case. Remove yoke (16).

16. Remove seal (17).

17. Remove four bearings (18).

18. Remove four bolts (19) and two locks. Remove gear (20).

19. Remove washer (21).

20. Push retainer (22) down with two screwdrivers and remove the two locks and spring from the stud.

21. Remove the retainer, locks and springs from the other three studs.

22. Install two 1/2″-13 NC forged eyebolts in the bracket. Remove the bracket, ring and collar as a unit from the plate assembly.

23. Remove plate assembly (23).

24. Remove two bearings (24).

25. Remove four pins (25) with a hammer and punch.

26. Remove four links (26).

27. Remove the two lock assemblies (27) and ring (28) from the bracket.

28. Disassemble the four links as follows:

a. Remove the pin from link (30) and rollers (29).

b. Remove the link and rollers from the link.

29. Remove four bolts (31) from collar (32).

30. Remove collar (32) from collar (34).

31. Remove four springs (33) and pins from collar (34).

32. Remove washer (35).

33. Remove the two blocks (36).

34. Remove washer (37) from washer (38).

Assemble Flywheel Clutch (Direct Drive & Special Application)

1. Put washer (37) in position on washer (38).

2. Install the two blocks (36) on the collar. Install the two cotter pins that hold the blocks in position.

3. Install washer (35).

4. Install the four pins in the collar.

5. Install collar (32) in the correct position over the springs and pins (33).

6. Install the four bolts and two locks that hold the collar in position.

7. Install the two rollers (29) and link (30) in the link as shown.

8. Install the pin that holds the rollers and link in position.

9. Assemble the other three link assemblies. Follow Steps 7 and 8.

10. Put ring (28) in the bracket. Install the two lock assemblies (27).

11. Install the two pins (25) on each link assembly. Put the four link assemblies in position in the ring.

12. Put the collar in position in the ring. Install the four pins that hold the collar to the ring.

13. Install the two bearings in the plate assembly with tooling (A) and an arbor press. Install the bearings to a depth that is given in Step 14.

14. Install one bearing (24) in the plate assembly to a depth of dimension (X). Dimension (X) is 1.8125 in (46.038 mm). Install the other bearing in the plate assembly to a depth of dimension (Y). Dimension (Y) is 6.35 mm (.250 in.).

15. Position plate assembly (23) on the plate. Install four studs (K) in the plate.

16. Install two 1/2″-13 NC forged eyebolts in the bracket. Fasten a hoist to the bracket. Install the bracket, ring and collar as a unit on the plate assembly. Remove the hoist and eyebolts.

17. Install spring (F) over the stud. Put the retainer (22) over the spring and push the retainer down with two screwdrivers. Install the two locks around the stud and release the tension on the retainer. Make sure the retainer and locks are in the correct position on the stud. Install the other three springs, retainers and locks on the three studs.

18. Install washer (21).

19. Install gear (20) and the two locks and four bolts that hold the gear in position.

20. Install the two outside bearings in the flywheel clutch case with tooling (B). Install the bearings until they are even with the bottom of the counterbore in the case. Install the two inside bearings in the case with tooling (B). Install the two bearings until they are even with the inside surface of the case.

21. Install the lip type seals in the flywheel clutch case with tooling (C). Install the seal with the lip toward the inside of the flywheel clutch case and until the seal makes contact with the bottom of the counterbore in the case. Put clean SAE 30 oil on the lip of the seal.

22. Put the yoke (G) in position in the flywheel clutch case. Slide the shaft (14) into the flywheel clutch case and into the yoke. Install the two keys in the shaft.

23. Install the two bolts and washers that hold the yoke in position on the shaft.

24. Install the bearing in the cage with tooling (D). Install the bearing until it makes contact with the bottom of the counterbore in the cage.

25. Install the retainer that holds the bearing in position.

26. Install a new O-ring seal on the cage. Put 1P808 General Purpose Lubricant on seal (H).

27. Install the seal in the cage with tooling (E). Install the seal with the lip toward the bearing in the cage. Make sure the seal is even with the outside surface of the cage.

28. Put clean SAE 30 oil on the lip of the seal.

29. Heat bearing race (24) to a maximum temperature of 275°F (135°C). Install the bearing race on the shaft. Make sure the race is in contact with the shoulder on the shaft.

30. Put the drum in position on the shaft. Install the four bolts that hold the drum in position.

31. Install cage (10) and the six bolts that hold the cage in position.

32. Fasten a hoist to the flywheel clutch case. Put the flywheel clutch case in position over the clutch group. Remove the hoist.

33. Install lever (9) on the shaft.

34. Put the shaft (2) in the flywheel clutch case and into the clutch group.

35. Install the flywheel clutch brake.

36. Install the flywheel clutch oil pump.

End By:

a. install flywheel clutch.

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