Hi Jerryv,
I don't plan on using a new belt. The one that was installed still has a lot of life left on it, so I will replace it when it needs to be.
As for the reassembly:
What I started off with was putting the piston/thrust plate in the housing for the fan. I lightly greased both o-rings and the entire plate and set it aside. I applied a fair amount of grease (but not gobs of it) to the housing where the o-rings on the plate slide, as well as the three guides. After putting the plate into the housing, I used brake cleaner to clean the face of the thrust plate, and set the assembly aside. Similarly to the thrust plate, I lightly greased the entire thrust cap and degreased the face. The hard part would have been mating the housing and the thrust cap with the clutch disc and spring. Fortunately I found it much easier to put a piece of threaded rod through the center of the assembly and use nuts to compress the whole apparatus; this way there was no fighting the spring and thrust cap in order to get the screws in. You cannot compress the spring all the way down using this method because you will eventually run into the spacer that sits in the center of the spring on top of the bearings. Once the holes are aligned it is easy to Loctite each screw and put it in. I used Loctite 271- the PDF from Evans says to use 272, but I couldn't source any locally. At first I mis-read the PDF and almost put 70 ft-lbs on a screw... it is 70 INCH-lbs! It didn't matter anyway, because I didn't have any torque-wrenches that could do 70 in-lbs so I just tightened them by hand with a screwdriver using star-pattern to ensure the thrust-cap is evenly torqued.
After that fiasco was complete, it was easy to drop the fan-side housing into the rest of the clutch (a bit tricky to align the clutch disc with the posts inside, but it can be done) and apply the remaining spacer, spring washer, and lock-nut. I then applied grease to the o-rings and threads on the cap and installed it. Since assembly was complete at this point, I then verified that I could spin the two halves freely. Hooking it up to an air source at ~10psi, I was able to lock the clutch up and verify it was functioning. There is a small hole on the outside of the fan-housing, near the base of the cap that releases air pressure to disengage the clutch. Be sure that it clear of any debris, otherwise the clutch will stay locked. This may be an issue for those who are encountering a stuck-on fan.
As for the studs that I removed when removing the nuts for the fan, I used the same Loctite 271 to lock them in place. For good measure when mounting the fan, I decided I will use some lock-washers in addition to the lock-nuts it already has.
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