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Interference Between Clutch Damper and Flywheel Bolts On 2003-2006 Caterpillar 3406E C-15 & C-16 Diesel Engines The AERA Technical Committee offers the following information regarding possible interference between the clutch damper and flywheel bolts on 2003-2006 Caterpillar 3406E, C-15 and C-16 diesel engines. Engines built or serviced with the VCT plus clutch damper, introduced in April 2003, have the possibility of the clutch damper interfering with the flywheel mounting bolts. This applies to the following clutch part numbers: 108009-32Y, 108925-20, 108925-25, 108926-20Y, 108926-25Y, 109701-20, 109701-25, 109705-20Y, 109705-25Y & 109706-32Y. Correction/Action: Any repair that has required the transmission to be removed from the truck, and the engine serial number is 5EK1 and up, 6TS1 and up, 1LW1 and up, 2WS1 and up, 6NZ1-92122, 7CZ1-04382, MBN1-21447, BXS1-00984, 5DS1 and up, or 1MM1 and up, requires checking the flywheel bolt washers. You must verify the 5mm washer has been replaced with the 3mm washer, Caterpillar Part Number 8D-5054. Failure to replace the washers could result in damper rivet interference. Torque the bolts to 270 Nm +/- 40 Nm (200 ft/lb +/- 30 ft/lb). It is also suggested that paint may be applied to bolt heads to show verification and completion identification.
This tutorial is provided as a courtesy by ECS Tuning. Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety. Although this material has been prepared with the intent to provide reliable information, no warranty (express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or damage resulting from reliance on this material. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material. VW Jetta MKIV Stage 1 Clutch Kit Installation
[b] If clutch contact face is scored or worn, the flywheel may be refaced. [c] If clutch contact face is cracked, the flywheel must be replaced. NOTE: Do not remove more than 0.508 mm (0.020 in.) material from the flywheel. Maintain all of the radii when resurfacing. 2. Inspect the ring gear. [a] Check ring gear for excessively worn or damaged gear teeth. [b] If damaged gear teeth are detected, replace the ring gear. Refer to Section 1.15.3. 3. Inspect crankshaft and flywheel contact surface. [a] Check the butt end of the crankshaft and flywheel contact surface for fretting, brinelling, or burrs. See Figure 1-212. [b] Lightly stone the contact surface to remove any fretting, brinelling, or burrs. Figure 1-212 1.14.3 Crankshaft and Flywheel Mating Surfaces Installation of Flywheel Install the flywheel as follows: 1. Install two flywheel guide studs, J 36235, into two of the tapped holes in the crankshaft at the 3 and 9 o’clock position. 2. Attach the flywheel lifting tool and, using a chain hoist, position the flywheel in the flywheel housing. Align the flywheel bolt holes with the crankshaft bolt holes. All information subject to change without notice. (Rev. 2004) 6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION From Bulletin 2-50-04 1-261 1.14 FLYWHEEL NOTICE: A new scuff plate must be used whenever the flywheel is removed. Failure to replace the scuff plate may cause the flywheel bolts to loosen, even when torqued correctly. 3. Using a new scuff plate, install two bolts with International Compound #2® (or equivalent) through the plate 180 from each other. 4. Install the flywheel lock, J 36375–A. See Figure 1-195. 5. Remove the flywheel lifting tool and guide studs. 6. Apply International Compound #2® (or equivalent) to the threads and to the bolt head contact area (underside) of the remaining bolts. The bolt threads must be completely filled with International Compound #2® (or equivalent). Any excess must be wiped off. See Figure 1-213.
New flanged multi-point socket head bolts have been released to prevent the MBE 900 pilot bearing from walking out of the flywheel housing. The new bolts will replace two flywheel bolts, located 180 degrees from one another. KIT CONTENTS The MBE 900 Pilot Bearing Bolt Service Kit P/N: A9269900105, consists of the following parts, listed in Table 1: Part No. A9269900005 18SP666 Table 1 Qty. 2 1 Description Flanged Multi-point Socket Head Bolts Installation Instructions MBE 900 Pilot Bearing Retaining Bolt Service Kit (P/N: A9269900105) INSTALLATION PROCEDURE Use the following procedure to install the new flanged multi-point socket bolts: 1. Shut off engine and apply the parking brake, chock the wheels, disconnect vehicle battery power, and perform any other applicable safety steps. 2. Remove the transmission. 3. Remove clutch from flywheel. 4. Pull the crankshaft position sensor out of the flywheel housing about 8 mm (0.32 in.). 5. Remove the end cover from the flywheel housing and install the engine barring tool (J-46392). Tighten the bolts on the barring device to 25 N·m (18 lb·ft). Insert the locking pin to block the device and prevent it from rotating. 6. Using J-46385, the flywheel and main pulley socket tool, remove two flywheel multi-point socket head bolts from the flywheel, 180 degrees apart. See Figure 1.
CLUTCH DISC: Please note, after installing AA flywheel and new clutch disc, the vehicles should be driven moderately to seat the disc properly. LIMITED LIABILITY: All flywheels are manufactured for off-road use applications and are considered racing parts. Active Autowerke will not be responsible or liable for labor, incidental or consequential damages of any kind. E36 M3 Flywheel Installation he front section of driveshaft has to come down. p the center support too. The insulation was removed right after the exhaust. Disconnect the clutch slave cylinder, the electronic connection elps. Especially for the starter mounting bolts. p the center support too. The insulation was removed right after the exhaust. Disconnect the clutch slave cylinder, the electronic connection elps. Especially for the starter mounting bolts. the old that needs to be replaced with a AA Clutch Fork. On 96-99 models to maintain the proper clutch release point. Note you might hav he pressure plate on with a hand impact. DO NOT USE AIRTOOLS! Airtools will likely strip the heads of the hex bolts, they're soft. Get a ham ct so you can get the flywheel off.
The major cause of clutch failure is excessive heat. Excessive heat generated between the flywheel, driven discs, intermediate plate and pressure plate can cause the metal to flow and the material to be destroyed. If this occurs, the clutch can burst which can cause property damage, serious bodily injury or death. In order to prevent clutch failure resulting from excessive heat: 1. Do not exceed recommended vehicle loads. 2. The clutch should only be used for the recommended applications. 3. Drivers should be properly trained in starting, shifting and operation of the clutch. 4. Drivers should report erratic clutch operation as soon as possible to permit maintenance personnel to inspect, adjust or lubricate as required. 5. The removal and installation procedure described for each component may vary for your vehicle. For Solo and Heavy-Duty ECA clutches only, install shipping bolts before removing clutch assembly from the flywheel. IMPORTANT For service information and assistance, call the Roadranger Help Desk at 1-800-826-HELP (4357) (Mexico: 01-800-826HELP (4357). You may also find more information about Eaton Clutches at www.Roadranger.com. Mechanics must be familiar with proper clutch adjustment, linkage adjustment, lubrication and other maintenance troubleshooting procedures outlined in the Failure Analysis Guide. Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation makes no warranty, expressed or implied, based on the information provided.
For P/No: 04998 & 04999 only. 1. In the engine bay, disconnect the negative and positive battery terminals. 2. Remove the vehicle battery (1) by first removing any fasteners. 3. Locate the vehicle grommet behind the battery cavity area. 4. Pierce a hole in the vehicle grommet. Note: Do not connect the harness to the battery at this point. Issue Date 27-09-10 For P/No: 04997 only. 5. In the engine bay, locate the vehicle battery (1). 6. Route the body harness (2) down through to the chassis. Note: Do not connect the harness to the battery at this point. 7. Route the power input harness (1) from the engine bay down through to the chassis, following the path of the brake and fuel lines. For P/No: 04997 & 04999 only. 8. Following the diagram on the right, house the two power & ground input harness female terminals (4) into the mating connector (3). 9. Connect the power input harness connector (3) to the body harness mating connector. Issue Date 27-09-10 For P/No: 04998 only. 10. Following the diagram on the right, house the three power & ground input harness female terminals (4) into the mating connector (5). 11. Connect the power input harness connector (5) to the body harness mating connector. 12. Route the body harness (1) along the LHS chassis rail, following the path of the blue vehicle harness towards the rear of the vehicle. 13. Route the body harness (1) along the rear of the vehicle towbar towards the towbar mounting bracket. Issue Date 27-09-10
Australian Competition and Consumer Commission 23 Marcus Clarke Street, Canberra, Australian Capital Territory, 2601 © Commonwealth of Australia 2013 This work is copyright. In addition to any use permitted under the Copyright Act 1968, all material contained within this work is provided under a Creative Commons Attribution 3.0 Australia licence, with the exception of: • the Commonwealth Coat of Arms • the ACCC and AER logos • any illustration, diagram, photograph or graphic over which the Australian Competition and Consumer Commission does not hold copyright, but which may be part of or contained within this publication. The details of the relevant license conditions are available on the Creative Commons website, as is the full legal code for the CC BY 3.0 AU licence. Requests and inquiries concerning reproduction and rights should be addressed to the Director, Internal Communication and Publishing Services, ACCC, GPO Box 3131, Canberra ACT 2601, or email@example.com. Important notice The information in this publication is for general guidance only. It does not constitute legal or other professional advice, and should not be relied on as a statement of the law in any jurisdiction. Because it is intended only as a general guide, it may contain generalisations.
Throughout this article I will address many basics of your vehicle’s steering, suspension, driveline, tires, and wheels. I did not intend this to be a “how to” manual with step by step instructions. It will simply illustrate the concepts. I’ll start with the lift and explain what it did to your steering, suspension, and driveline one aspect at a time. NOTES ABOUT THE ILLUSTRATIONS: 1) most are “spring under” leaf spring suspension, 2) non-pertinent parts are omitted for clarity, 3) many examples are exaggerated for illustration, and 4) most concepts illustrated also apply to spring over and coil/link suspensions. To cover the differences, I added a separate coil and link suspensions topic. Ready? OK, let’s get started. You lifted your Jeep and now it wanders all over the road and it vibrates too. What happened? Well, you just changed a lot of the vehicle’s geometry (probably without knowing it). Here’s a diagram of a stock Jeep and the proper angles. Your caster angle should be between 4 and 8 degrees positive. This caster angle creates an effect called mechanical trail. It’s the force that makes your wheels return to center. The caster angle shown below is close to stock. The point that the steering axis (black line) intersects the ground to the point to where the rotational axis touches the ground forms the points to measure your caster angle. You can best measure the caster angle from the top of the upper ball joint.
1 TON FOLDING ENGINE STAND Model 47304 ASSEMBLY AND OPERATING INSTRUCTIONS ® 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at http://www.harborfreight.com Copyright © 2002 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools . For technical questions and replacement parts, please call 1-800-444-3353 Specifications Engine Stand Capacity Assembled Dimensions Folded Dimensions Engine Turn Capacity Main Post Height 1 Ton (2000 Lbs.) 42” L x 36” W x 34” H 17” L x 22-1/2” W x 40” H 360 Degrees 32-1/2” Save This Manual You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference. Safety Warnings and Precautions WARNING: When using product, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment. Read all instructions before using this product! 1. Avoid working alone. If an accident happens, an assistant can bring help. 2. Keep work area clean. Cluttered areas invite injuries. 3. Observe work area conditions. Don’t expose to rain. Keep work area well lighted. 4. Keep children away. Children must never be allowed in the work area. Do not let them near the Stand. 5. Store idle equipment. When not in use, the Stand must be stored in a dry location to inhibit rust. Always lock up tools and keep out of reach of children. 6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts. Protective, electrically nonconductive clothes and nonskid footwear are recommended when working. Wear restrictive hair covering to contain long hair. 7. Use eye and ear protection. Always wear ANSI approved impact safety goggles. 8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across electrical cables or frames. 9. Maintain Stand with care. Inspect Stand, and if damaged, have it repaired by an authorized technician. SKU 47304