Trying to get the fan clutch to line up with the hub to remove, any ideas??

Yes, that will. I have seen them just get rusty and stick. But if you wanna take the hub off. Pull the whole thing. You will be much happier than trying to disassemble the hub from the spindle in the truck. Trust me. Plus the stud sticking out the front breaks alot. Then you have to pull it anyhow.

 

Can you spread it apart enough to go over the hub? On some service calls I have cut the friction disc in half 180 degrees from the split. Then replaced the old one.
Repaired the 1/4 plastic air line with a hole in it. That caused low air pressure to the hub and smoked the friction disc.

 

New material will go over the hub.

 

I do not understand some of your questions so I will just start at the first post.
Do you know there are allen head bolts in the holes between the studs sticking out the front. If you remove them you maybe able to move the fan and clutch forward. Then remove the hub without leaning the radiator forward.
That is a Kysor clutch and there is nothing wrong with that. When I worked for a company we repaired a lot of them. Anymore I just replace them as it is not worth the risk and or down time.
Cut long cardboard in strips about 12 inches wide. Then work them in behind radiator to help protect it. Still be very careful as those studs are core killers.
I went back and reread some and other posts make more since now. Like kit masters for Horton But for Kysor I only buy new.

 

Same here. Replaced many Kysor (now Borg Warner) on the side of the road. I know we received extended warranty on our KW's and replaced with upgraded clutch. Spec all with two-speed Hortons nowadays.

 

A fleet of ours had too many fans go through the rad and swapped all to horton. Only order em with horton now.