1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirelyvoluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefro
2、m, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243TO PLACE A DOCUMENT
3、 ORDER; (724) 776-4970 FAX: (724) 776-0790SAE WEB ADDRESS http:/www.sae.orgCopyright 1997 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.SURFACEVEHICLE400 Commonwealth Drive, Warrendale, PA 15096-0001RECOMMENDEDPRACTICEJ2407ISSUEDOCT1997Issued 1997-10Clutch Installation a
4、nd Release Linkage Requirementsfor Truck and Bus ApplicationForewordThis document is presented in response to OEM requests for uniform installation parameters. It alsoidentifies truck clutch release linkage performance standards required for successful clutch operation.TABLE OF CONTENTS1. Scope . 11
5、1 Purpose 12. References . 22.1 Applicable Documents 22.1.1 SAE Publications 23. Definitions. 24. Technical Requirements. 34.1 Pre-Installation Storage 34.2 In-Process Handling . 34.3 Installation 34.3.1 Engine Flywheel Preparation 34.3.2 Clutch Unit Installation 34.3.3 Clutch Unit Adjustment. 44.3
6、4 Transmission Preparation . 44.3.5 Transmission Installation. . 44.3.6 Clutch-Release Linkage Installation and Setting 54.3.7 End of Line Inspection 54.4 Process Documentation. 54.4.1 Fixtures, Gages, Specific Tools, and Torque Wrenches . 54.4.2 Installation, Assembly, Lubrication, Inspection, Eva
7、luation, and Repair Processes . 51. ScopeAlthough not limited to, these installations are normally used on trucks considered as Medium Duty(Class 6 and 7), as well as Heavy Duty (Class 8).1.1 PurposeThis SAE Recommended Practice defines vehicle assembly plant clutch installation procedures,adjustmen
8、t criteria, and clutch-release linkage performance parameters required to obtain optimum clutchoperation and to promote standardization for pull type single- and twin-plate truck clutches.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J2407 Issued OCT1997
9、2-2. References2.1 Applicable PublicationsThe following publications form a part of the specification to the extent specifiedherein. Unless otherwise indicated the latest revision of SAE publications shall apply.The following publications define the existing clutch system design configuration used
10、in trucks and busses:2.1.1 SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth, Warrendale, PA 15096-0001SAE J373Housing Internal Dimensions for Single and Two Plate Spring Loaded Clutches SAE J617Engine Flywheel HousingsSAE J1463Pull Type ClutchTransmission Installation DimensionsSAE J1479Automoti
11、ve Pull Type Clutch TerminologySAE J1731Pilot Bearings for Truck and Bus ApplicationsSAE J1806Clutch Dimensions for Truck and Bus ApplicationsSAE J1857Flywheel Dimensions for Truck and Bus Applications3. DefinitionsThe following specific terms as used in this document are defined as follows:3.1 Alig
12、nment ToolAn arbor or shaft made to fit into the clutch disc splines and having a front pilot diametermade to fit closely in the flywheel pilot bearing.3.2 Clutch Cover Assembly Guide PinsSteel rods threaded to fit into the flywheel threaded clutch-mountingholes with a body diameter closely fitting
13、within the cover assembly mounting screw holes and having a lengthlonger than the normal clutch-mounting screws. The exposed end of the pins is rounded or chamfered andcontains a screwdriver slot or similar feature to aid in their removal.3.3 Clutch Shipping Blocks or Shipping ClipsDevices inserted
14、into the clutch cover assembly by itsmanufacturer to hold the pressure plate partially retracted to aid in its installation. These shipping blocks orclips are to be reinstalled whenever the clutch is removed.3.4 Heavy-Duty (Class 8) TrucksA truck or tractor rated by the manufacturer and certified to
15、 the US federalgovernment to be for operation at a gross vehicle weight or a gross combination weight of 14969 kg(33001lbs) and over.3.5 Lube TubeA rubber hose with fittings at each end used to remotely locate a grease fitting away from thethreaded hole it is usually inserted in.3.6 Medium-Duty (Cla
16、ss 6 and 7) TrucksA truck or tractor rated by the manufacturer and certified to the USfederal government to be for operation at a gross vehicle weight or a gross combination weight of 8846 kg(19501 lbs) to 14969 kg (33000 lbs).3.7 OEM Original Equipment ManufacturerThe term used to identify a vehicl
17、es manufacturer.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J2407 Issued OCT1997-3-4. Technical Requirements4.1 Pre-Installation StorageClutches received for vehicle builds should be:a. Checked when received to assure shipping containers arrived intact
18、 and clean with identification labelsattached and legible. There should be no evidence of water damage, rust, or contamination.b. Stored in a location that will protect them from rust.c. Stored in a location having a low probability of accidental physical damage to both the clutch and itsshipping co
19、ntainer.d. Stacked no higher than clutch manufacturers recommendations. e. Stored such that identifying labels can be clearly read without moving containers.4.2 In-Process HandlingRecommended procedures are:a. To move clutches from the storage area to the installation area with proper equipment and
20、care so asto prevent contamination and rough handling or droppage.b. To remove the clutches carefully from the container and bring them to the engines flywheel withoutrough handling or droppage.4.3 InstallationA successful clutch system installation requires the following:4.3.1 ENGINE FLYWHEEL PREPA
21、RATION:a. Rust preventatives must be removed from the clutch friction surface, clutch damper cavity- and pilot-bearing cavity.b. Pilot bearing must be installed using proper tooling and checked for a good press fit, correct seating,and free spinning operation.c. For heavy-duty 14-in pot flywheels, t
22、he six intermediate plate drive pins must be installed using propertooling and fixed in place with correctly installed set screws. Additionally, some types of clutchesrequire three anti-rattle straps placed between the drive pins and correctly installed.4.3.2 CLUTCH UNIT INSTALLATION:a. Driven disc
23、orientation must be confirmed as correct (“flywheel side” to flywheel).b. Clutch lifting and handling equipment and procedures must be appropriate so as to avoid bending,damage, or droppage.c. Clutch mating to flywheel must be accomplished using an appropriate clutch disc alignment tool andclutch co
24、ver assembly guide pins or support fixture to prevent pilot-bearing damage, while bringing theclutch unit into proper alignment with the flywheel mounting bolt holes.d. Clutch-mounting bolts of the correct type, size, and length must be selected for the clutch unit beinginstalled.e. Clutch-mounting
25、bolts are all to be hand started before final tightening is begun.f. Heavy-duty flat flywheel clutches must be checked to insure the cover assembly is properly positionedto enter the flywheel pilot rim.g. Clutch mounting bolts must be torqued in an alternating star pattern starting at the lower left
26、handcorner. Bolt torque requirements are: 3/8 in size 34 to 47 Nm (25 to 35 lbs/ft)7/16 in size 54 to 68 Nm (40 to 50 lbs/ft)h. Clutch shipping blocks (2) or shipping clips (4) must be removed from the clutch unit if they fail to fallout.i. Some types of clutches require the intermediate plate sepa
27、rator pins to be set to the flywheel using a6 mm (1/4 in) flat faced punch.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J2407 Issued OCT1997-4-4.3.3 CLUTCH UNIT ADJUSTMENT:a. Clutch adjusting fixture is attached to rear face of engine flywheel housing.
28、b. Using the adjusting fixture, the clutch release travel gap is checked and the clutch unit adjusted asrequired to obtain a release travel gap between the rear of the release bearing and the front of thetransmission or input shaft brake of 12.7 mm to 14.3 mm (0.500 in to 0.562 in). Some clutchinsta
29、llations without an input shaft brake have a larger OEM specified release travel gap. For thesevehicles, a special fixture or unique indicator setting are required to obtain the correct gap. c. Some types of clutches for use without an input shaft brake do not use the adjusting fixture. Instead,they
30、 are adjusted to obtain a specific gap between the back of the clutch cover assembly and the frontof the clutch-release bearing as specified by the clutch manufacturer. Appropriate approved gages orfixtures must be used to obtain the correct adjustment.d. Some types of clutches require an adjustment
31、 locking procedure which must be accomplished perclutch manufacturers recommendations.e. Clutch-driven discs must be checked to insure that they spin freely when the release bearing is pulledrearward to the release position.f. Remove clutch disc alignment tool without damaging pilot bearing.g. Insta
32、llations with “lube tubes” for remote application of ball-bearing grease must have the tubes 100%pre-filled with a Lithium-base ball-bearing grease recommended by the clutch manufacturer.4.3.4 TRANSMISSION PREPARATIONFor this process, it is assumed that the correct transmission, clutch-releaseyoke,
33、cross shafts, and external control lever have been selected for installation:a. Inspect the transmissions cross-shaft bushings and grease fittings to make sure they are properlyoriented and not restricted.b. Assemble the cross shafts through the cross-shaft bushings and into the correctly oriented r
34、eleaseyoke being careful not to allow the cross shafts to protrude through the release yoke.c. Torque release yoke bolts and external control lever mounting bolt to OEM specifications.d. Release yoke/cross shaft and lever sub-assembly must be rotated to be sure there is freedom ofmovement and no bin
35、ding.4.3.5 TRANSMISSION INSTALLATION:a. Engine flywheel housing rear face and bore surfaces must be visually inspected to be sure they arefree of burrs, nicks, dirt, rust, or excessive paint.b. Transmission clutch-housing front face and pilot surfaces must be visually inspected to be sure theyare fr
36、ee of burrs, nicks, dirt, rust, or excessive paint.c. Rotate the release yoke so the fork tips are pointing forward and are as high as possible.d. Installations with an input shaft brake must have it installed on the shaft at this time and pushed as farrearward as possible.e. Place the transmission
37、in direct drive or overdrive.f. Using appropriate lifting devices, bring the transmission into correct straight alignment with the engineand move it forward to insert the input shaft into the clutch-release bearing bore.g. Continue to move the transmission forward with a minimum of angular movement
38、rocking) to avoidclutch damage while simultaneously rotating the release yoke fork tips down into the normal usageposition. Some types of clutches can be damaged if the release yoke is not rotated down at this time.h. Rotate the transmission output shaft as necessary to correctly align the transmis
39、sion input shaft splinewith the clutch-driven disc splines during the final phase of transmission insertion. Push thetransmission fully forward until the clutch-housing pilot is seated against the flywheel housing bore.Rotate the transmission as necessary to align the mounting bolt holes.i. Maintain
40、 transmission lifting support while the transmission mounting bolts are installed and tightenedto OEM specification.j. Release yoke/cross shaft and lever sub-assembly must be rotated to be sure there is freedom ofmovement and no binding.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Info
41、rmation Handling ServicesSAE J2407 Issued OCT1997-5-4.3.6 CLUTCH RELEASE LINKAGE INSTALLATION AND SETTINGFor this process, it is assumed that the correctsystem components have been selected for installation: a. Some types of release linkages use rods which are adjustable for length with some to be a
42、djusted to apre-determined length prior to installation. Appropriate gages or fixtures must be used to verify correctrod length prior to installation and locking nut torque must be to OEM specification.b. During linkage component installation, process instructions must be consulted to insure thecomp
43、onents are installed in the correct locations with the correct orientation.c. Some types of release systems have adjustable “stops” for the clutch pedal travel in the “up” position orthe “down” position, or both. Appropriate gages or fixtures must be used to assist in making theseadjustments.d. Some
44、 types of release systems are composed of rigid mechanical components which do not includean automatic clutch wear compensating feature. These systems must be adjusted to provide a “freetravel” gap between the release yoke fork tips and the release bearing housing contact point of 2.7 mmto 3.7 mm (0
45、105 in to 0.145 in). Appropriate gages or fixtures must be used in making the finalrelease linkage setting adjustment to insure the free travel gap at the release-bearing is withinspecifications and that locking nut torque is to OEM specification.e. Some types of release systems are composed of eit
46、her rigid mechanical components, pneumaticdevices, or hydraulic devices which do include an automatic clutch wear compensating feature. Thesesystems operate without freeplay. Some of these systems require post-installation adjustments at thepedal, or transmission, or both. Appropriate gages or fixtu
47、res must be used to assist in making theseadjustments. Hydraulic systems require 100% complete hydraulic fluid fill without fluid leakage andwith correct reservoir fill levels. Appropriate OEM specified processes are required to assurecompliance.f. Clutch-release yoke cross-shaft bushings and often
48、other components of the release system requirelubrication. OEM specified process instructions and check lists should be used to insure all requiredgrease points are correctly lubricated.g. Installations with an input shaft brake must not engage the brake when the clutch pedal is 25.4 mm(1.00 in) or
49、more above its fully depressed position. The input shaft brake must fully engage before theclutch pedal is fully depressed. The input shaft brake is fully engaged when a 0.25 mm (0.010 in)feeler gauge is held snugly between the input shaft brake and the clutch-release bearing.h. Throughout the full clutch pedal operating range, all moving components of the clutch-release systemmust operate without any contact or interference with any other vehicle component.4.3.7 END OF LINE INSPECTION:a. A customer pre-delivery inspection of the vehicle should include
