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CLUTCH ADJUSTMENT PROCEDURE
NOTE: Meritor Clutches are adjusted at the factory to original equipment specifications, and should require very little internal adjustment to achieve
proper release and engagement. The clutch must not be adjusted to accommodate thin or worn flywheels, or worn linkage, yoke and/or cross shaft
bushings, or to accommodate other deficiencies. Adjustment for such purposes will either cause the clutch to function improperly or will cause early clutch
failure, and will be apparent on factory inspection of warranty claims... and therefore will void the manufacturer warranty.
THIS PROCEDURE COVERS BOTH 14" AND 15 1/2" CLUTCHES WHEN A CLUTCH BRAKE IS USED
STEP #1
After clutch installation, check the clearance between the yoke tips and wear pads on bearing housing for 1/8" clearance. This determines pedal free play.
(see illustration)
Adjust the clutch linkage to increase or decrease the yoke-to-bearing clearance. NEVER USE THE INTERNAL CLUTCH ADJUSTMENT
FOR THIS PURPOSE.
STEP #2
Check for proper clutch brake and bearing gap of 1/2" to 9/16". If the gap is not within these tolerances add or remove the fiber spacer or the clutch
needs adjusting.
If the clutch does need adjusting, remove the lock strap or turn the quick adjuster and set the clearance between the bearing and clutch brake at 1/2" to
9/16". THIS DIMENSION IS CRITICAL. DO NOT VARY — EITHER OVER OR UNDER THESE DIMENSIONS — UNDER ANY
CIRCUMSTANCES. Over adjusting either way will cause the clutch to slip or not release.
Use the internal adjustment on the clutch to move the bearing. Turn adjuster clockwise to move bearing towards transmission (to decrease clearance) or
counter clockwise to move the bearing towards the engine (to increase clearance). If internal adjustment exceeds 4 notches either way the clutch may not
release or may slip.
Put tension on the linkage to be sure bearing is stretched and no movement towards the engine is noticed. Measure clutch brake and bearing gap with
1/2" - 9/16" gauge (see illustration). Once the adjustment is set, re-install lock strap. Make sure quick adjuster is in the locked position.
REMINDER: The bearing must move a minimum of 1/2" or clutch will not release. Eliminate lost motion before checking for 1/2" movement. Lost
motion is generally caused by loose or worn linkage, or worn yoke or cross shaft bushings.
STEP #3
If internal clutch adjustment was made re-verify the 1/8" clearance between the yoke tips and wear pads on bearing housing shown in Step #1 above (see
illustration). If necessary, re-align linkage to obtain proper clearance.
STEP #4
Re-verify the clutch brake squeeze by inserting .010 feeler gauge between bearing and clutch brake, then depressing the pedal to end of stroke. The feeler
gauge must be tightly clamped between the bearing and the clutch brake. This verifies the contact of the bearing to the clutch brake.
The clutch brake will be squeezed if the total pedal stroke slightly exceeds the movement required to move the yoke/fork 5/8" to 11/16" (the combined
total of the 1/8" clearance between yoke tips and wear pads and the 1/2" - 9/16" brake squeeze gap.
IN THE EVENT THE BRAKE IS NOT BEING SQUEEZED, DO NOT CHANGE THE 1/2" - 9/16" GAP FOR THE CLUTCH
BRAKE, OR THE 1/8" CLEARANCE FOR THE BEARING HOUSING. CONSULT THE VEHICLE MANUFACTURER SERVICE
MANUAL.
In analyzing the reasons for the brake not being squeezed, other things to check for are:
A. Worn linkage components or yoke and cross shaft bushings. If necessary, replace those components.
B. Improper linkage assembly. Verify that linkage is assembled in the correct hole locations.
C. Pedal stroke. To adjust, raise the upper and/or lower the lower pedal stops.
NOTE: MAXIMUM BRAKE SQUEEZE (IN CAB OF TRUCK) SHOULD NOT EXCEED 1" FROM THE END OF PEDAL STROKE. IF IT DOES, IT CAN BE ADJUSTED BY:
A. Changing pedal stops in cab to reduce total pedal stroke.
B. Increasing 1/8" yoke-to-bearing setting to lower squeeze. (this will increase free-pedal travel)
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