Zman,
I’m guessing you are working on a 05 by your screen name.
There was a change in the clutches in 2002. Barnett’s catalog is a bit screwy. It shows the difference when you look at the individual parts but it is showing the same part numbers for the kits.
Barnett Link
1999-01 Friction K-1100(8)_K-900K(2)
Steels HP-27-20(7) HP-27-23(2)
Complete kit *TM-42K *TM-42CF
2002-05 Friction K-1100K(8)_K-900K(1) HDP-13B(1)
Steels HP-27-20(7) HP-27-23(2)
Complete kit *TM-42K *TM-42CF
For a 05 you should have 3 different friction plates and two different steel plate. The friction that goes inside has a smaller inside diameter, so less surface area (it is also thicker). The one on the outside is thicker than the rest. (by .032).
Did you get 3 different Friction disks or two? In the diagrams at the bottom, notice part number 14 and 15 are not in the lower one. The lower one is the 99-01. If you are using the 99-01 style plates with the cush ring (14-15 in the upper) you are going to have problem.
Download the service manual at the top of the page. The clutch is for the 99-01 style but it has some good info.
Pages 3-66 3-112 3-113 10-3-3
The outside plate is also “clocked†different from the rest. See the illustration on page 3-112
Springs. Yes, I think you should replace them. Mine lost .050†in free length. The .050†of loss meant it had 5lbs less pressure per spring. That is 30lbs total or almost like removing one spring from a new set!
Clutch stack height can also reduce spring pressure.
Old clutch, what did it look like? Do you have a picture of the plates and fibers? If the fibers were wasted, you may need to clean your oil screen of debris.
Link to pictures ... I'll fix it later to display here.
02-06
99-01
