Instruction Sheet

IS-04106B

CLUTCH AND RADIATOR FAN TRANSFER MECHANISM
MOUNTING BASE REPLACEMENT
REVISION :
B
A : KIT #052665 HAS BEEN MODIFIED
B : KIT #052665 MODIFIED – 500177 added (3X) – Do not use bolts supplied with 550879

MATERIAL
Kit #052665 includes the following parts:
Part No.

Description

Identification

Qty

052624

Arm, Belt Tensioner

1

052670

Pivot, Belt Tensioner Arm

1

500270

Washer, Flat SS .406 X 1 X .063

1

052676

Roller, Idler Assembly

1

983296

Screw, Cap Hexagonal Head, ZP M20X90 G10.9

1

5001252

Nut, Hexagonal Stover M20-2.5

1

5001628

Nut, Hexagonal

1

052691

Plate, Reinforcement Clutch Support

1

052584

Pulley, Gearbox

1

052649

Mounting Base, Radiator Fan Transfer Mechanism (500 HP Fan Drive)

1

052652

Plate, Support

1

052655

Attachment, Spring

1

052667

Hose, 1524 mm long

1

142013

Bracket, Air Pressure Regulator

1

500948

Screw, Thread- cutting Hex Head ZP ¼-20 X 1

2

5001208

Bolt, Carriage ZP M8X30

3
IS-04106B / Page 1/8

Formulaire QF2150959

Rev:1

500218

Washer, Split-Lock 3/8 X 11/16 X 3/32

1

500449

Washer, Flat SS 5/8 X 1½

4

500734

Nut, Hexagonal Jam ZP ¾-16

1

500832

Washer, Flat 13/32 X 13/16 X 1/16

1

500874

Washer, Flat ZP 21/64 X 43/64 X 1/16

3

500897

Washer, Flat 7/16 X 1 X 5/64

4

504013

Mount, Cable Tie

4

500642

Screw, Tapping Binding Head, Phillips ZP #10 X ¾

4

501027

Connector, Male Tube ¼ FL X ¼ NPT

1

501808

Elbow, Male 45° ¼ tube 45° FL X 1/8 NPT

1

501036

Elbow, Male 90° ¼ tube 45° FL X 1/8 NPT

1

501894

Tee, Male Branch ¼ NPT

1

641332

Connector, Male ¼ tube X 1/8 NPT/push-in tube

1

641371

Elbow, Male ¼ tube X ¼ NPT/push-in tube

1

504637

Tie, Black Cable

12

503402

Tube, Black ¼ (1 X 5 feet long)

5

502247

Spring, Compression 1¼ x 2½ x 1/8

1

502543

Nut, Hexagonal ZP M8-1¼

3

502889

Washer, Split-Lock 5/16 X ½ X 5/64

3

502917

Nut, Hexagonal Jam ¾-16 G2

1

502926

Screw, Cap Hexagonal Head 3/8-16 X 7/8 LG

1

5060071

Belt POLY V 12PK

2

507293

Bushing, Nylon 5/8 X 11/16 X 11/32 X 15/16

8

509815

Wire Clamp, Quick Mounting (Fir Tree Base)

3

550186

Key

1

550839

Clutch, Fan 500HP

1
IS-04106B / Page 2/8

550840

Bellows, Air 4 inch dia.

1

550879

Sleeve, Coupling

1

500177

Screw Cap Hex ZP 1/4-20X1 G8

3

630062

Isolator, Rubber Vibration

2

507347

Bushing for rubber vibration isolator

2

640488

Valve, Air Pressure Check

1

641472

Regulator, Air Pressure

1

955920

Washer, Split-Lock 17/64 X 31/64 X 1/16

3

971083

Nut, Hexagonal Stover M10-1.5

4

IS-04106B

Instruction Sheet

1

FI-04106B

Feuille d'instructions

1

PROCEDURE
WARNING

Park vehicle safely, apply parking brake, stop engine and set battery master switch(es) to the
OFF position prior to working on the vehicle.
1.

Locate the belt tensioner air pressure regulator then turn pressure releasing valve counterclockwise
(clockwise for H series vehicles) to release the pressure from the air bellows. Make sure all applicable
safety precautions were taken.

2.

Remove the belts from gearbox and fan clutch.

3.

Unfasten the bolts fixing gearbox onto mounting base then remove gearbox.

4.

Remove fan drive pulley from gearbox.

5.

Remove the bolts fixing the 3-inch air bellows attachment brackets which are located near the
gearbox, and then put the attachment brackets aside.

6.

Unfasten the fitting at the base of belt tensioner arm.

7.

Unfasten the bolts fixing the fan to the clutch in order to facilitate removal of mounting base.

8.

Disconnect the clutch power cable connector, note wire color coding;
o Brown wire – Pin A
o Blue wire – Pin B
o Yellow and green wire – Pin C

9.

Unfasten the bolts fixing the clutch onto the mounting base then remove the clutch.

WARNING

Use a loading tripod such as a gin to adequately support the radiator fan transfer mechanism
mounting base while removing the supporting legs fixing bolts.
10. Remove the bolts fixing the mounting base supporting legs.
11. Using the gin, lift and remove mounting base from engine compartment.
IS-04106B / Page 3/8

NOTE
Clean radiator fan transfer mechanism mounting base location as required.
12. Dismount belt tensioner arm from former mounting base, keep the arm, flat washer and nut as well
as grease fitting. Set parts aside.
13. Install and secure the new mounting base (052649) onto a workbench then install the belt tensioner
arm pivot (052670) on the new mounting base using flat washer (500270) and nut (5001628).
14. Install the belt tensioner arm on its pivot making sure the nylon bushings (507293) are properly
inserted then secure the belt tensioner arm using the flat washer and nut. Screw the grease fitting in
then grease the pivot.

NOTE
You may have to clean inside the belt tensioner arm pivot hole to facilitate nylon bushing insertion.
15. Install idler roller assembly (052277) and spring attachment (052655) on the belt tensioner arm and
secure them using the former bolt and nut.
16. Install 4-inch diameter air bellows (550840), and then fix it onto the belt tensioner arm using its flat
washer, split-lock washer and capscrew (502926). Apply some Teflon paste on 90° elbow (501036)
threads then screw elbow in the base of the air bellows.
17. Install compression spring (502247) between mounting base and spring attachment.

NOTE
In the case of XL and XLII vehicles, compression spring and its attachment will probably not be used.
This is normal and was anticipated.
18. Fix gearbox onto new mounting base using split-lock washers and bolts.
19. Install pulley (052584) onto gearbox. Fix pulley coupling sleeve (550879) to mounting flange using
key (550186) and 3 supplied 500177 screws (do not use the three 1 3/8” screws supplied with the
coupling sleeve) referring to plays indicated in figure 3.
20. Install support plate (052652) onto fan clutch (550839) then install fan clutch onto mounting base and
secure using 3 carriage bolts (5001208), flat washers (500874), split-lock washers (502889) and nuts
(502543) (Refer to figure 1).

NOTE
In the case of H3 vehicles, use support plate foremost oblong holes; use rearmost oblong holes in the
case of XL or XLII vehicles. This will ensure proper fan clutch positioning with reference to the radiator
shroud.
21. Install reinforcement plate (052691) onto fan clutch support
22. Route clutch power cable along the mounting base as per figure 2. Fix power cable connector onto
reinforcement plate bracket using 2 nylon cable ties (504637). Drill 7-mm holes in order to install
quick mounting wire clamps (509815) (504637) so as to secure cable.

CAUTION
Make sure that enough play exists and that the cable does not run into the clutch or mounting
base during clutch operation.
23. Insert the 2 rubber vibration isolators (630062) into the mounting base supporting legs then insert the
2 bushings (507347) inside the isolators.
24. Using the gin, lift the mounting base assembly in order to install it in the engine compartment.
IS-04106B / Page 4/8

FIGURE 1

FIGURE 2

IS-04106B / Page 5/8

25. Use the gin to safely support the fan transfer mechanism mounting base while inserting the
supporting legs fixing bolts. Install washers and tighten nuts.
26. Use a straight edge to properly align fan clutch pulley with gearbox pulley. Install belt (5060071) over
fan transfer mechanism pulleys, slightly unfasten gearbox fixing bolts in order to pivot the gearbox
and properly align belt on the pulleys (Refer to figure 3). Retighten fixing bolts.

NOTE
Two belts are supplied (one for spare).
27. Fix the fan onto the clutch using the supplied bolts.

CAUTION
Verify that play around fan blades is even and that blades do not touch the shroud when the
clutch is in 1st or 2nd speed. Adjust the play by lifting or lowering the clutch.
28. Fix bracket (142013) of 2nd air pressure regulator (641472) using two thread cutting screws (500948).
Install bracket onto rear cap interior wall (XL or XLII) or onto a cross member above the fan transfer
mechanism in the case of H3 vehicles.

NOTE
2nd

air pressure regulator may be installed in various places depending on equipment installed. Use
supplied hose (052667) to help deciding on proper location.

29. Fix air pressure regulator onto bracket using nut (500734).
30. Unscrew existing air pressure regulator inlet fitting. Apply some Teflon paste then install a male
branch T-fitting (501894) on existing regulator air inlet. Apply some Teflon paste then screw 90° male
elbow push-in tube fitting (641371) into the T-fitting on the fan transfer mechanism side. Reinstall the
pressure releasing valve fitting on the other side of the male branch T-fitting.
31. Depending on the chosen location for 2nd regulator, cut the appropriate length of air tubing (503402),
apply some Teflon paste on the push-in tube male connector (641332) then screw it into the 2nd
regulator air inlet port. Connect two push-in tube male fittings using air tubing. Apply some Teflon
paste onto the air pressure check valve (640488) then fasten it to the 2nd regulator.
32. Locate 3-inch air bellows located near the gearbox, remove T-fitting installed at the base and replace
it with a 45° elbow (501808). Reinstall the air bellows attachment brackets.
33. Apply some Teflon paste on male tube connector (501027) then screw it into the 2nd regulator air
outlet, use hose (052667) to connect 4-inch air bellows with 2nd regulator air outlet.
34. Fix black air tubing using cable tie mounts (504013), tapping screws (500642) and nylon cable ties
(504637). Fix hose (052667) using clamps and nylon cable ties (504637).
35. Reinstall belts on engine pulleys.
36. Turn belt tensioner pressure releasing valve clockwise (counterclockwise for H series vehicles) to
reapply the pressure on the belts. Set 2nd regulator pressure to 35 lb/in2.
37. Check operation of radiator fan transfer mechanism in 1st and 2nd speed.

IS-04106B / Page 6/8

FIGURE 3

IS-04106B / Page 7/8

FIGURE 4

IS-04106B / Page 8/8