Usage:
1. Cool end cap (34) in a freezer or with dry ice for future installation.
2. Using FT2461 Pressing Bar (31) install, sleeve bearing (32) 2.92 mm (.115 in) from the top of the hub (arrow). Install the other sleeve bearing (33) 44.45 mm (1.750 in) from the top of the hub (arrow).
3. Apply 5P3321 Adhesive on the seal retainer (35) ID.
4. Using FT2462 Pressing Tube (29) and FT2463 Ring (47) install seal retainer (35) on the fan mounting hub. Press the seal flush with the shoulder. Remove all excess adhesive.
5. Apply 5P3321 Adhesive to the inside of the front wear sleeve (36).
6. Using FT2462 Pressing Tube (29), press front wear sleeve (36) onto the fan mounting hub until the tool stops on the shoulder.
NOTE: The front wear sleeve is colored red on the ID, do not interchange with the rear wear sleeve. Clean off all excess adhesive.
NOTE: Do not polish, scratch or mar wear sleeve ground surface. This could cause seal leakage. The surface was ground with a machined lead.
7. Coat the end cap bore with 5P3321 Adhesive.
8. Press the end cap (34) to the bottom of the fan mounting hub.
9. Apply 7M7456 Bearing Mount on the OD of the bearing (30).
10. Using FT2465 Plate (28), press bearing (30) in bearing retainer (7). Press the bearing to the bottom of the bearing retainer.
11. Install internal snap ring (26) to hold the bearing in place.
12. Use 5P3321 Adhesive on the OD of the seal (27).
13. Use FT2465 Plate (28) to install front oil seal (27).
14. Install the seal flush and straight.
15. Wipe off excess adhesive and remove rubber strings after installation into bore.
16. Coat the inside of the bearing with 7M7456 Bearing Mount Compound.
17. Use FT2462 Pressing Tube (29) and FT2463 Ring (47) to press the bearing/retainer subassembly onto the fan mounting hub.
NOTE: After pressing the components into position, spin the bearing retainer on the fan mounting hub (with the oil contact surface dry), to "burnish" the seal lip contact area on the wear sleeve.
18. Install backing plate (16) to clutch hub (14) with snap ring (15).
19. Use 5P3321 Adhesive on the dowels (21).
20. Press dowels (21) into the clutch body.
21. Press the dowel flush with the clutch body side (48).
22. Install large seal ring (18) to the clutch body.
23. Lubricate surface (49) of the clutch body with oil to ease assembly.
24. Install small seal ring (23) on the piston housing (22). Install the O-ring (19) on the clutch body.
25. Install the piston housing (22) on the clutch body.
NOTE: Do not force the clutch body past the seal ring (23). Adjust the seal ring so the clutch body passes through it without damage.
26. Make sure the dowels properly enter the dowel holes (not the cast grooves) in the piston housing.
27. Use 5P3321 Adhesive at location (50) on the balance plate (18).
28. Install balance plate (18) with internal snap ring (17).
NOTE: A facing plate (12) will be on the top and the bottom of the stack of plates.
29. Install the clutch hub subassembly with a woodruff key (24) to the fan mounting hub.
30. Install facing plates (12) and clutch plates (13) as shown.
31. Install spring washer (11) and wear plate (10).
32. Use 9S3263 Thread Lock on the threads.
33. Thread the body subassembly onto the front unit finger tight.
34. Clamp the "bar" of FT2466 Mounting Plate (9) in a vise. Locate the bar in the notches of clutch body (8).
35. Bolt FT2467 Rotating Plate (4) to fan mounting hub (5). Use washers to fill gap if necessary.
36. Tighten the clutch to a torque of 270 to 305 N·m (200 to 220 lb ft).
37. Use 5P3321 Adhesive on the ID of the seal retainer (41).
38. Use FT2462 Pressing Tube (29) and FT2463 Ring (47) to press on seal retainer (41). Press flush with shoulder. It must be straight. Wipe off all excess adhesive.
39. Use 5P3321 Adhesive on ID of rear wear sleeve (42).
NOTE: Rear wear sleeve is colored blue on the ID. Do not interchange with front wear sleeve.
40. Use FT2462 Pressing Tube (29) to press wear sleeve (42) on the shaft.
41. Press wear sleeve onto the shaft until the tool stops on the shoulder. Do not polish, scratch or mar the ground surface on the wear sleeve. The surface was ground with a machined lead. Wipe off all the excess adhesive.
42. Realign the match-mark (from disassembly) if both the pulley and pulley adapter are being used again. If either the pulley or pulley adapter are new, locate the "Heavy Side" indicators stamped on the flanges. [H] These must be located 180 degrees apart to obtain the best balance.
43. Tighten the bolts (1) to a torque of 46 to 58 N·m (34 to 43 lb ft).
44. Use 7M7456 Bearing Mount Compound on OD of bearing (44).
45. With FT2465 Plate (28) install rear bearing (44) into the pulley adapter. Press to bottom.
46. Install internal snap ring (39) into the pulley adapter.
47. Apply 5P3321 Adhesive to the oil seal (43).
48. Use FT2465 Plate (28) install oil seal (43) into the pulley adapter. Press the seal flush and straight.
49. Wipe off the excess adhesive and remove rubber "strings" after the installation into the bore.
50. Apply 7M7456 Bearing Mount Compound to the ID of the bearing.
51. Using FT2462 Pressing Tube (29) press the pulley adapter/pulley on the shaft and bracket assembly.
52. Press to the bottom off the shoulder. Wipe off the excess adhesive.
53. Use 5P3321 Adhesive on the inside of the ring and tube assembly.
54. Use FT2462 Pressing Tube (29) and FT2463 Ring (47) to press ring and tube assembly (39) onto the shaft. Make sure the tubes curve counterclockwise when viewing down into the adapter. Press to the bottom, to clear the snap ring groove.
55. Install snap ring (37) on the shaft.
56. Install hook-type seal rings (36) on the shaft.
57. Lubricate hook-type seal ring area to ease assembly.
58. Install O-ring (3) and the clutch assembly on the shaft.
59. Install washers (2) and bolts (1). Tighten the bolts to a torque of 23 to 27 N·m (17 to 20 lb ft).