Clutch Rotor and/or Bearing Replacement HT6/HD6/HU6

Tools Required

1. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .



2. Remove the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub Assembly Removal .
3. Use the J 6083 in order to remove the following components:

•	The pulley rotor (1)

•	The bearing assembly retaining ring (2)




4. Install the J 33023-A to the front head.
5. Install the J 41552 down into the inner circle of slots (1) in the rotor.



6. Turn the J 41552 clockwise in the slots in the rotor.
7. Perform the following steps in order to remove the pulley rotor and bearing assembly:

7.1.	Hold the J 41552 in position.

7.2.	Tighten the puller screw against the puller guide.

7.3.	Remove the pulley rotor and bearing assembly.

8. Use the following procedure to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage:

8.1.	Remove the forcing screw from the J 41552 .

8.2.	Ensure that the puller tangs still engage in the rotor slots.

8.3.	Invert the assembly onto a solid flat surface or blocks.

Notice: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged.

9. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub.

Notice: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent.

1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation.
2. Use the following tools in order to align the new bearing squarely with the hub bore:

•	The J 41552

•	The J 9481-A

•	The J 29886

3. Drive the bearing fully into the hub.

The installer will apply force to the outer race of the bearing, if used as shown.




4. Place the J 33019 in the hub bore.
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the staking pin location.

Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin.

Important: Use care in order to prevent personal injury when striking the staking pin with a hammer.

6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing.




Important: Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing.

7. Stake 3 locations on the bearing race 120 degrees apart as shown.



8. With the compressor mounted on the J 34992 , position the pulley rotor (1) and the bearing assembly on the front head.
9. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
10. Position the J 8433-1 on the J 33023-A .
11. Assemble the 2 through bolts and the washers through the puller bar slots.
12. Thread the through bolts into the J 34992 .

Ensure that the thread of the through bolts engage the full thickness of the J 34992 .

13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head.

If the J 33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps:

13.1.

Loosen the J 8433-3 .

13.2.

Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head.




14. Use the snap ring pliers in order to install the following components:

14.1.

The pulley rotor (1)

14.2.

The retaining ring (2)

14.3.

Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate/Hub Assembly Install .

14.4.

Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .