NHTSA ID Number: 10130768
Manufacturer Communication Number: IK1100032
TSB/Document Date: 2018-04-02
Summary
Hydraulic Clutch Diagnostic & Service Information; only models with a Manual Transmission and Eaton
Advantage Solo Self-Adjusting Clutch
IK1100032 - LT, RH Hydraulic Clutch Diagnostic & Service Information
Page 1 of 11
Countries:
CANADA, UNITED STATES Document ID: IK1100032
Availability:
ISIS, NotSIR
Revision:
5
Major System:
CLUTCH
Created:
6/29/2017
Current Language: English
Last Modified: 12/20/2017
Other Languages: NONE
Author:
Viewed:
Caleb Iverson
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Title : LT, RH- Hydraulic Clutch Diagnostic & Service Information
Applies To : LT, RH, Equipped with a Manual Transmission and Eaton Advantage Solo Self-Adjusting
Clutch
CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
12/20/2017- Added RH to "Applies To"
09/11/2017 - Formatting corrected
08/16/2017 - Updated parts notes, only one slave cylinder is required for repair: hydraulic with air assist or hydraulic clutch without air assist.
07/03/2017 Added Eaton Manual links
06/30/2017 Initial Article Release
DESCRIPTION
This iKNow document is designed to outline the specific clutch service procedures with hydraulic clutch release
systems.
SYMPTOM(s)
Customer Observations or Concerns:
Spongy Pedal
Won't go into gear
No clutch brake
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
DTC/Light
Description
N/A
N/A
SPECIAL TOOL(s) / SOFTWARE
Tool Description
Tool Number
Comments
Instructions
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IK1100032 - LT, RH- Hydraulic Clutch Diagnostic & Service Information
Hand Operated Vacuum Pump
Tester
ZTSE2499
Solo Clutch Resetting Tool
RR1005CL
Clutch Measurement Tool
RR1007CL
Page 2 of 11
Vacuum Bleed Procedure
Hand Operated Vacuum Pump Tester - ZTSE2499
SERVICE PARTS INFORMATION
Kit Description
Part Number
Quantity
Required
CYLINDER, CLUTCH OPERAT,
3868300C94
1
CYLINDER, CLUTCH OPERAT OR
MAST 35.7MM ID
3866376C91
1
CYLINDER, CLUTCH OPERAT AIR
ASSIST OR MAST 35.7MM ID
3866377C91
1
HOSE FLEX HYDRAULIC CLUTCH
3953848C1
1
CLAMP, PIPE SGL-CUSHIONED 7/16 ID
X .281 MOUNTING
98959R1
2
BOLT M6 X 25 PHC CLS 10.9
30194R1
2
M6 X 25
NUT, HEXAGON HEAD FLANGE CLASS
10 M6
40233R1
2
M6 X 25
WASHERS, FLAT METRIC
1696027C1
4
M6
1 GALLON BRAKE FLUID
428104C1
1
Notes
Order only if
not equipped
Air Assist
Order only if
equipped with
Air Assist
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IK1100032 - LT, RH Hydraulic Clutch Diagnostic & Service Information
Page 3 of 11
DIAGNOSTIC STEP(s)
To prevent property damage, personal injury, and / or death, keep flames or
sparks away from vehicle and do not smoke while servicing the vehicle’s
batteries. Batteries expel explosive gases.
To prevent property damage, personal injury, and / or death, remove the ground
cable from the negative terminal of the battery box before disconnecting any
electrical components. Always connect the ground cable last.
To prevent property damage, personal injury, and / or death, if the vehicle must be raised,
do not work under the vehicle supported only by jacks. Jacks can slip or fall over.
To prevent personal injury and / or death, always wear safe eye protection
when performing vehicle maintenance.
To prevent property damage, personal injury, and / or death, park vehicle on a hard, flat
surface, turn the engine off, set the parking brake, and install wheel chocks to prevent the
vehicle from moving in either direction.
Step Action
Decision
Continue to Step 2.
If symptoms above are present, replace the master cylinder, air assist servo
#1 cylinder hose, and the hydraulic hose between them.
Step Action
#2
Decision
Continue to Step 3.
Perform re-routing procedure here. Then perform the clutch bleeding procedure
outlined here.
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IK1100032 - LT, RH Hydraulic Clutch Diagnostic & Service Information
Step Action
DIAGNOSTIC:
Page 4 of 11
Decision
Yes. Continue to Step 4.
Measure clutch pedal free-play using Clutch Measurement Tool (RR1005CL):
#3 1. Depress the pedal by hand until the master cylinder begins to stroke.
No. Adjust Clutch Linkage follow the
Eaton Manual on Page 8.
Is clutch pedal freeplay between 0.4" and 0.6"?
Step Action
DIAGNOSTIC:
Decision
Yes. Continue to Step 5.
Measure release bearing gap using clutch measurement tool (RR1007CL).
#4 See page 8, step 3 of Eaton Manual for reference, if needed.
No. Perform In Vehicle Resetting
Procedure in the Eaton Manual on page
14.
Is release bearing gap .490" to .560"?
Step Action
DIAGNOSTIC:
Decision
Yes. Finish repairs and release truck.
Measure clutch brake squeeze:
1. Insert 0.010" feeler gauge between release bearing and clutch brake
2. Measure how far the clutch pedal is from the floor at time of release of 0.010"
#5 feeler guage.
No. Repeat Step 2.
See page 9 of Eaton Manual for reference, if needed.
Is clutch brake sqeeze 1" from the floor?
REPAIR STEP(s)
Routing and Clipping
Master Cylinder Supply Hose Routing
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IK1100032 - LT, RH- Hydraulic Clutch Diagnostic & Service Information
Page 5 of 11
Figure 1. Incorrect Master Cylinder Supply Hose Routing
Item 1: Ptrap
Item 2: Master Cylinder Inlet level
Note: In Figure #1 you can see that the master cylinder supply hose is clamped down to the air assist servo cylinder supply
hose. This creates a ptrap (aeration) at the master cylinder. To remove the air from the system, proper routing must be
achieved.
1. Cut 2 zip ties holding the master cylinder supply hose down to the air assist servo cylinder supply hose.
Figure 2. Correct Master Cylinder Supply Hose Routing
Item 1: New Supply Hose Clipping Points
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IK1100032 LT, RH Hydraulic Clutch Diagnostic & Service Information
Page 6 of 11
Figure 3. Top View of Cowl Tray
Item 1: Drilling locations
2. Drill 2 holes in the approximate location (Figure 3, Item 1) in the cowl tray using a 1/4" drill bit.
3. Using 2 bolts, 2 nuts, 4 washers and 2 pclamps secure the master supply hose to the cowl tray.
Air Assist Servo Supply Hose Routing
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IK1100032 LT, RH- Hydraulic Clutch Diagnostic & Service Information
Page 7 of 11
Figure 4. Incorrect Air Assist Servo Cylinder Supply Hose Routing
Item 1: Saddle clamp on the wrong side of transmission cooler lines
Item 2: Saddle clamp
1. Disconnect the air hose from the air assist servo cylinder.
2. Cut the zip tie at the saddle clamp (Figure 4, Item 2).
Figure 5. Correct air assist servo Cylinder Supply Hose Routing
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IK1100032 LT, RH- Hydraulic Clutch Diagnostic & Service Information
Page 8 of 11
Item 1: Air line routed over transmission cooler lines
Item 2: Saddle clamp
Item 3: Extenion Brake Repositioned
3. Re-position the extenion bracket (Figure 5, Item 3) bolted to the air assist servo cylinder as high as possible without causing a
hose rub condition.
4. Re-route the air line over the transmission cooler lines (Figure 5, Item 1).
5. Secure the air line to the air assist servo cylinder supply hose with a new zip tie to the saddle clamp (Figure 5, Item 2).
6. Re-insert the air line into the air assist servo cylinder air supply connection.
Bleeding Procedure
Hand Operated Vacuum Bleeding Procedure
1. Pull vehicle into the shop, apply parking brake, chock wheel and open hood.
2. Drain air tanks.
Figure 6. Reservoir Hook-up
3. Fill a clean container full of brake fluid (at least a quart).
4. Install reservoir adapter cap.
5. Insert tube from reservoir adapter cap into container full of brake fluid, submerge until 10mm from the bottom of the
container.
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IK1100032 LT, RH- Hydraulic Clutch Diagnostic & Service Information
Page 9 of 11
6. Set container full of brake fluid on the cowl to allow gravity feed.
Figure 7. Air Assist Servo Bleeder Screw
Item 1: Bleeder Screw
Item 2: Hand Operated Vacuum Pump Suction Hose
Item 3: Air Assist Servo
7. Set-up hand operated vacuum pump to the air assist servo bleeder screw.
8. Pump hand operated vacuum pump up to 15” of mercury and then open the bleeder screw.
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IK1100032 LT, RH- Hydraulic Clutch Diagnostic & Service Information
Page 10 of 11
Figure 7. Hand Operated Vacuum Pump
9. Continue pumping keep vacuum needle between 10” and 15” of mercury.
10. Once container on hand operated vacuum pump is full, close the bleeder screw.
11. Release the pressure in the hand operated vacuum pump by pressing the relief valve.
12. Dump the brake fluid into an empty container.
13. Set-up the hand operated vacuum pump again to pull vacuum.
14. Pump hand operated vacuum pump up to 15” of mercury and then open the bleeder screw.
15. Continue pumping keep vacuum needle between 10” and 15” of mercury, while doing this have an assistant press the clutch
pedal twice. Perform this step three times.
16. Adjust fluid level to max level.
17. Install battery/skirt cover.
18. Return to step 3 in step based diagnostics.
WARRANTY INFORMATION
Group: 11000 - Clutch
Noun: 352 - Hose / Pipe
Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.
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IK1100032 LT, RH Hydraulic Clutch Diagnostic & Service Information
Page 11 of 11
Standard Repair Time(s)
Description
Chassis
SRT
Hours
Hydraulic master cylinder, hydraulic hose, and air assist servo cylinder
replace
Re-route hoses
Includes Vacuum Bleed Procedure
LT
T-Time
2.0 HRS
Standard Repair Time(s):
Refer to the SRT Manual for Repair Times
OTHER RESOURCES
Master Service Information Site
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Copyright © 2018 Navistar, Inc.
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TSB/Document ID: IK1100032
Replacement Service Bulletin Number:
MFR Communication Date: 2017-12-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, HYDRAULIC:PEDALS AND LINKAGES
MFR Component System:
MFR Component Subsystem:
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