SB-10054410-3759

Clutch-Related No-Start Diagnostics
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

Century Class Conventional
Argosy COE
Cargo
Columbia

Coronado
Business Class M2
> Cascadia
108SD/114SD

25-34
Freightliner
Service Bulletin

Description of Revisions: This bulletin replaces the version dated
December 2012. The list of symptoms and troubleshooting diagnostics have been revised.

General Information
Cascadia vehicles equipped with Eaton manual transmissions may experience no-start faults that are associated with the clutch position combination switch (clutch control switch). Recent investigations have exposed two
possible causes, and this bulletin should be used to determine the cause of the problem. Use the procedure in
this bulletin, and service information published on www.AccessFreightliner.com and www.RoadRanger.com,
to diagnose and repair the problem, if the following symptoms are present:
• engine not starting
• engine has trouble starting/is hard to start
• transmission grinding going into starting gear
• excessive clutch brake wear
• early clutch brake squeeze
• clutch pedal not returning after it has been pressed
The listed symptoms can be caused by one of the following:
• Clutch Over-Adjust: It is possible that Eaton clutch pressure plates can become over-adjusted in normal
service. In the most severe cases, the clutch brake will contact the release bearing before the pedal will
close the "clutch open" switch.
• Clutch Position Combination Switch: Deposits can accumulate on the contacts of the clutch position
combination switch, causing high resistance.

Diagnostics
Follow the steps below to identify the failed part.
1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2. Make sure the batteries are charged. Turn the ignition key ON.
3. Connect the vehicle to the ServiceLink diagnostic tool. Select the SAM Cab ECU, then go to the "Templates" tab and select "Starter Relay, Crank Enable." See Fig. 1.
4. While pushing the pedal to the point of clutch brake squeeze (Fig. 2), check the SAM Cab Template. Does
the actuation of the pedal switch register? The actuation of the pedal is registered when the "Bottom of
Clutch Circuit" indicator turns green and reads "At Bottom," as shown in Fig. 3.

If NO, go to the next step.
If YES, the system is not experiencing any of the failures covered in this bulletin. Discontinue the use of this
Service Bulletin and continue with normal diagnostics for the rest of the starting system; see Cascadia
Troubleshooting Manual, P01.01—Starting and Charging.

Freightliner Service Bulletin, September 2013

Page 1

25-34
Freightliner
Service Bulletin

Clutch-Related No-Start Diagnostics
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

Century Class Conventional
Argosy COE
Cargo
Columbia

Coronado
Business Class M2
> Cascadia
108SD/114SD

A

B
C
05/22/2003

f250617

A. Clutch Free-Pedal
B. Clutch Release-Pedal
C. Clutch Brake Squeeze
Fig. 2, Clutch Pedal Movement
12/07/2012

f120241

Fig. 1, ServiceLink Template Menu

5. Continue to monitor the SAM Cab ECU while having an assistant open the bleed valve on the slave cylinder (see Fig. 4), allowing the pedal to travel all the way to the floor. Have the assistant close the valve.
Does the actuation of the pedal switch register on the "Bottom of Clutch Circuit" indicator? If necessary, top
off fluid with DOT 4 brake fluid.

If NO, the actuation of the pedal does not register, go to the next step.
If YES, the actuation of the pedal registers, go to step 8.
6. Disconnect the chassis harness from the clutch position combination switch. See Fig. 5.
7. Use a jumper wire to close the clutch low position control circuit on the chassis side (between pins A and C
in Table 1), and look for a response on the SAM Cab ECU template. Does the response register on the
template?

If YES, replace the switch with the newer version that is marked with a yellow dot, indicating the seal has
been removed. See Cascadia Workshop Manual, Section 25.01, Subject 150.
If NO, the system is not experiencing any of the failures covered in this bulletin. Discontinue the use of this
Service Bulletin and begin using the standard diagnostics for the specific symptoms experienced.

Page 2

Freightliner Service Bulletin, September 2013

Clutch-Related No-Start Diagnostics
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

Century Class Conventional
Argosy COE
Cargo
Columbia

Coronado
Business Class M2
> Cascadia
108SD/114SD

12/07/2012

25-34
Freightliner
Service Bulletin

f120242

NOTE: Cascadia SAM versions 6.0 and 6.2 template shown. Version 5.4 template is similar.
Shown with "Bottom of Clutch Circuit" indicator (circled) registering pedal actuation.
Fig. 3, "Starter Relay, Crank Enable" Template

Freightliner Service Bulletin, September 2013

Page 3

25-34

Clutch-Related No-Start Diagnostics

Freightliner
Service Bulletin

FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

Century Class Conventional
Argosy COE
Cargo
Columbia

Coronado
Business Class M2
> Cascadia
108SD/114SD

1

2

11/30/2010

f250682

1. Slave Cylinder

2. Bleed Valve

Fig. 4, Slave Cylinder Bleed Valve

Clutch Position Combination Switch
Diagram

Connector

A

B

C

Blue

—

Black

C
A
A

B

C
03/19/2007

03/19/2007

f545006

f545004

Table 1, Clutch Position Combination Switch, Bottom of Clutch Control

8. Remove the clutch inspection cover.
9. Using a telescoping bore gauge, measure the gap between the clutch brake and the release bearing, then
measure the gauge with a digital caliper. The distance should be more than 0.48 inch (12 mm). See Fig. 6.

If the distance is correct, install the inspection cover. Tighten the screws 14 to 18 lbf·ft (19 to 24 N·m). Replace the hydraulic pedal assembly. See Cascadia Workshop Manual, Section 25.01.
If the distance is less than 0.48 inch (12 mm), reset the clutch (see “Resetting the Clutch”).

Resetting the Clutch
1. With the parking brake applied and the tires chocked, have an assistant hold the clutch pedal down.
2. With the pedal held down, move the wear indicator tab to the left (NEW) position. See Fig. 7.

Page 4

Freightliner Service Bulletin, September 2013

25-34

Clutch-Related No-Start Diagnostics
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

Century Class Conventional
Argosy COE
Cargo
Columbia

Freightliner
Service Bulletin

Coronado
Business Class M2
> Cascadia
108SD/114SD

9
7
5

1

8

2

6
1

2

6

5

A
4
3
11/21/2012

1.
2.
3.
4.
5.

f250686a

Pedal Unit
Assist Spring
Hydraulic Hose
Clip
Bolt

6. Washer
7. Front Wall
8. Clutch Position
Combination Switch
9. Connector

Fig. 5, Clutch Pedal Assembly

09/16/2013

f250701

A. Measurement: more than 0.48 inch (12 mm)
1. Release Bearing
3. Telescoping Bore
2. Clutch Brake
Gauge
Fig. 6, Clutch Gap

1
E
AC
PL
RE

NE

W

2

f250428

06/04/97

With the clutch pedal down, set the tab to the "NEW"
position on the indicator.
1. Clutch Cover

2. Wear Indicator Tab

Fig. 7, Resetting the Wear Indicator Tab

Freightliner Service Bulletin, September 2013

Page 5

25-34
Freightliner
Service Bulletin

Clutch-Related No-Start Diagnostics
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

Century Class Conventional
Argosy COE
Cargo
Columbia

Coronado
Business Class M2
> Cascadia
108SD/114SD

3. If the cam moves, hold the adjustment tab in the new position, release the pedal, and go to step 7. If the
cam does not move, support the transmission and remove the clutch housing bolts. Install 1/2-inch spacers
between the clutch housing and the flywheel housing, then, with the clutch pedal held down, attempt to
reset the wear indicator tab again.
4. Remove the spacers, then install the clutch housing bolts. Tighten the bolts 43 to 53 lbf·ft (58 to 72 N·m) for
Patch-Lok capscrews, or 38 to 45 lbf·ft (52 to 61 N·m) for non-locking capscrews with lockwashers.

IMPORTANT: To prevent the clutch from returning to an over-adjusted position, the gaps between the
sleeves and pins have to be eliminated, as detailed below.
5. Install four shipping bolts (7/16-14 x 1-3/4 UNC) next to the sleeves and pins, as shown in Fig. 8. Tighten
the bolts so that the gaps between the sleeves and pins are eliminated.

1
1

1
A

2
1

3

1
4
08/02/2006

A. Gap Between Sleeve and Pin
1. Shipping Bolt
2. Sleeve

f250655

3. Pin
4. Access Panel
Fig. 8, Removing the Gap Between Sleeve and Pin

6. Remove the shipping bolts.
7. Push the clutch pedal down and squeeze the clutch brake five times to reposition the bearing, then recheck
the gap between the clutch brake and the release bearing. Does the gap return to less than 0.48 inch (12
mm)?

Page 6

Freightliner Service Bulletin, September 2013

Clutch-Related No-Start Diagnostics
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

Century Class Conventional
Argosy COE
Cargo
Columbia

Coronado
Business Class M2
> Cascadia
108SD/114SD

25-34
Freightliner
Service Bulletin

If NO, the gap is still greater than 0.48 inch (12 mm), replace the hydraulic pedal assembly. See Cascadia
Workshop Manual, Section 25.01.
If YES, the gap returns to less than 0.48 inch (12 mm), replace the clutch assembly. Follow the clutch replacement instructions in the Cascadia Workshop Manual.

IMPORTANT: Before clutch replacement, the dealer/repair facility must call Eaton Warranty for preapproval supported by a claim number (ETN). Ensure that four shipping bolts (7/16” x 1-3/4” UNC)
are installed to cage the clutch before removal from the flywheel. Return the clutch to Eaton Clutch
Division, with the claim number clearly marked on the outside of the box.

Warranty
Normal warranty applies.

Freightliner Service Bulletin, September 2013

Page 7