NHTSA ID Number: 10131157
Manufacturer Communication Number: IK1100031
TSB/Document Date: 2018-04-02
Summary
Hard to Crank Condition on Vehicles with Hydraulic Clutch Linkage and Solo Clutch
IK1100031 - Hard to Crank Condition on ProStar and LoneStar Vehicle
Page 1 of 5
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IK1100031
Revision:
1
Major System: CLUTCH
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10/29/2013
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10/29/2013
Matthew
Boyer
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Title: Hard to Crank Condition on ProStar and LoneStar Vehicle
Applies To: ProStar and LoneStar Vehicles with Hydraulic Clutch Linkage
and Solo Clutch
Description
ProStar and LoneStar model trucks built with Eaton
Solo Clutches may experience
a condition in which it is hard to get the vehicle to crank. This is caused by the
clutch bearing contacting the clutch brake prior to the clutch release pedal passing
the magnetic clutch safety switch, which closes the switch allowing the vehicle to
crank. This may cause increased or unattainable pedal efforts to allow the vehicle to
crank. The Eaton Solo clutch has been found to be operating lower than the clutch
specification of 0.490" - 0.560" bearing to brake, causing the decrease in clutch
release pedal movement.
Inspection
Remove the clutch inspection cover, and measure the bearing to brake position.
Inserting a bar that is about 0.500" is NOT an acceptable procedure for checking
the clutch bearing to brake measurement.
Preferred Procedure- Use a telescoping gage or inside caliper capable of a
0.400" - 0.600" range, and insert it between the clutch bearing and the clutch
brake aligned with the center of the brake and the center of the bearing. Then
measure the gage using a micrometer or a dial/digital caliper.
Alternate Procedure- Use a feeler gage set (shim stack), and stack the correct
number and size feeler gages to allow the feeler gage stack to fit snugly
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IK1100031 - Hard to Crank Condition on ProStar and LoneStar Vehicle
Page 2 of 5
between the clutch bearing and brake. Then measure the feeler gage stack
using a micrometer or a dial/digital caliper.
Rotate the engine over by hand until the clutch serial number is visible, and record
the clutch serial number.
Or
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IK1100031 - Hard to Crank Condition on ProStar and LoneStar Vehicle
Page 3 of 5
Clutch Release Bearing Free Travel Adjustment
If the clutch release pedal requires excessive effort to allow the vehicle to crank,
then adjust the clutch release pedal free travel to 0.700"-0.800" from the factory
setting of 0.400"-0.600". This allows the pedal to travel up to an extra 2-3 degrees,
allowing the vehicle to crank with reduced pedal effort force. Do not exceed 0.800",
or the clutch brake operation may be compromised.
Preferred Procedure- Use a dial indicator to measure the free play adjustment.
When setting up the dial indicator, adjust the indicator so the needle does not
slide across the pedal, but follows the pedal. The is the most accurate way to
measure the clutch release pedal free play, and will allow the final adjustment
point to be set accurately.
Alternate Procedure- This should only be done if a dial indicator is not
available. Using the tilt function on the steering column, align the steering
wheel to the clutch release bearing travel position. Use a piece of masking
tape and wrap the steering wheel in line with the clutch release pedal. Mark a
line on the masking tape and measure from the pedal to the line at the top of
the pedal range and at the bottom of the free play range. Using the tape
measure, adjust the clutch release pedal free play to 3/4".
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IK1100031 - Hard to Crank Condition on ProStar and LoneStar Vehicle
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IK1100031 - Hard to Crank Condition on ProStar and LoneStar Vehicle
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Post Adjustment Evaluation
After making the clutch pedal free play adjustment, depress the clutch pedal to
crank the vehicle. The starter should engage in a range from a little before to just
after clutch brake contact, which is indicated by the pedal coming to a stop with the
same amount of effort being applied to the clutch release pedal as was used to
stroke the clutch release pedal.
If the clutch internal bearing to brake measurement is less than 0.490", and
with the clutch release bearing free travel adjusted to 0.700"-0.800" the vehicle
does not crank, then the clutch will need to be replaced. Eaton Roadranger will
need to be contacted, with the current clutch bearing to brake measurement
and the clutch serial number. Eaton will either need to review the replacement
clutch serial numbers that you have in stock and provide you information on
which clutch to install, or will need to send you an appropriate clutch.
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Copyright © 2013 Navistar, Inc.
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TSB/Document ID: IK1100031
Replacement Service Bulletin Number:
MFR Communication Date: 2013-10-29
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN:CLUTCH ASSEMBLY
MFR Component System:
MFR Component Subsystem:
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