MAINTENANCE
INFORMATION
DATE :
SUBJECT :

MI16-07

MARCH 2016
SECTION: 05 - Cooling
Linnig LLW203 Angled Gearbox Clutch and Seals
Replacement Kits

IMPORTANT NOTICE
This modification is recommended by Prevost to increase your vehicle's performance. Note that no
reimbursement will be awarded for carrying out this modification.

APPLICATION
Model

VIN

X3-Series Vehicles
All vehicles equipped with Linnig LLW203 Angle Gear Box
H3-Series Vehicles

DESCRIPTION
Prevost is now offering a clutch replacement kit for vehicles equipped with a Kendrion (Linnig)
LLW203 Series fan clutch and gearbox assembly.
This kit will allow the replacement of the clutch alone, without the need to purchase a complete
assembly.
Along with this clutch kit, a complete seal replacement kit for the gearbox input and output shaft
is also being released to maximise the gearbox service life.
Procedure below describes the steps required to proceed to the clutch replacement
(manufacturer’s instructions are also included with the clutch kit).

MATERIAL
Order the following kits:
Part No

Description

Qty

551016

Repair Kit, Radial Shaft Seals

1

551017

Clutch Replacement kit

1

Other parts that may be required:
Part No.

551015

Description

Tool Kit, Gearbox

A

Holding device

B

Counter holder

C

Extractor tool

D

Mounting flange

E

Mounting shaft

F

Mounting sleeve

G

Hexagon screws

H

Flange nuts

I

Flange screws

Qty

1

MI16-07 / Page 3 / 9

PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.

1.

Drain oil from the angle
gearbox.

2.

Attach the holding device to
the bottom side of the angle
gearbox.

3.

Fix the holding device with
angle gearbox into a bench
vise.

4.

Attach counter holder to the
fan flange.

5.

Remove central hexagon
screw and disc at the clutch
side of the angle gearbox.

6.

Remove front part of the
clutch and rotor.

7.

Remove 4 socket head cap
screws.

8.

Remove magnet and spacer
sleeve.

9.

Remove central hexagon
screw and washer at the
output side of the angle
gearbox.

10. Remove flange and O-ring.

MI16-07 / Page 4 / 9

11. Remove radial shaft seal
rings at the input and output
side of the angle gearbox.

Attention: Do not damage
the gearing and the fitting
area of the shaft!

12. Remove O-ring at the clutch
side of the angle gearbox.

Attention: Do not damage
the gearing and the fitting
area of the shaft!

13. Grease new O-ring with
multipurpose grease and
slide it onto the clutch shaft.
14. Grease the outside diameter
of the new radial shaft seal
rings and the bore diameter
of the housing with
multipurpose grease.
15. Fill in multipurpose grease
between dust lip and sealing
lip of the new radial shaft
seal rings and press them
into the housing.
Attention: Open side of the
radial shaft seal ring must
face to the housing!

MI16-07 / Page 5 / 9

16. Clean the tread area of the
radial shaft seal ring at the
flange.

17. Slide flanges onto the
toothed end of the shaft at
the output side of the angle
gearbox.

18. Grease new O-ring with
multipurpose grease and
slide it onto the mounting
shaft.
(approx. 1 cm / 0.4po)

MI16-07 / Page 6 / 9

19. Screw mounting shaft with
new O-ring into the shaft end
at the output side of the
angle gearbox.

20. Slide mounting sleeve onto
the mounting shaft and
press the O-ring into the slot
between shaft and flange.

21. Apply Loctite 270 to the
thread of the new hexagon
screw, screw it with new disc
into the shaft and tighten it.
Torque Value:
135 Nm (100 lb-ft)

MI16-07 / Page 7 / 9

22. Clean the tread area of the
radial shaft seal ring at the
spacer sleeve and slide the
spacer sleeve onto the shaft
end.
23. Apply Loctite 270 to the 4
threads of the housing and
bolt on the magnet with 4
new socket head cap screws
Torque Value:
10 Nm (7 lb-ft)
Attention: Connector must
face upwards!

24. Slide rotor onto the toothed
end of the shaft.

25. Define no. of spacers that
are needed between the
front part of the clutch and
rotor to keep the air-gap
between
0.4 mm – 0.6 mm:
Measure the distance X
between shaft and outer
anchor plate (in red)

X ≥ 0.5 mm
X = 0.4 mm
X = 0.3 mm
X = 0.2 mm
X = 0.1 mm
X = 0.0 mm

 no spacer
 1 spacer
 2 spacers
 3 spacers
 4 spacers
 5 spacers

MI16-07 / Page 8 / 9

26. Slide new spacers onto the
shaft of the front part (see
point 25.) and center the
front part to the shaft end of
the angle gearbox.

27. Apply Loctite 270 to the
thread of the new hexagon
screw, screw it with new disc
into the shaft and tighten it.
Torque Value:
135 Nm (100 lb-ft)

28. Check the air-gap:
0.4 mm – 0.6 mm

MI16-07 / Page 9 / 9

29. Fill with new oil up to the
bottom line of oil level bore
(use supplied 400ml bottle in
551016 kit).

Torque value for filling,
draining and level plug:
35Nm (26 lb-ft).

Use only supplied Oil or
Linnig approved API GL-4
75W90 Synthetic Gear Oil.
(LINNIG specification 142.377)

PARTS / WASTE DISPOSAL
Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

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