NHTSA ID Number: 10156572
Manufacturer Communication Number: IK1100032
TSB/Document Date: 2019-04-03
Summary
Hydraulic Clutch Diagnostic & Service Information
IK1100032 - LT, RH- Hydraulic Clutch Diagnostic & Service Information
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Countries:
CANADA, UNITED
STATES
Document ID: IK1100032
Availability:
ISIS, NotSIR
Revision:
7
Major System:
Created:
6/29/2017
English
Last
Modified:
3/14/2019
Author:
David
Horner
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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:
03/14/2019 - Updated description, steps, formatting
01/09/2018 - New Article Owner
12/20/2017 - Added RH to "Applies To"
09/11/2017 - Formatting corrected
DESCRIPTION
This iKNow article is designed to identify and correct a hydraulic hose route & clip condition that may cause driver
symptoms listed below.
The route and clip condition exists when the hose between the reservoir and master cylinder does not have a
natural horizontal slope angle; thus, creating a sharp vertical slope angle (often referred to as a P Trap) on the hose
which prevents upward air bubble migration to the highest exit point (fluid reservoir) in the system (Figure 1)
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IK1100032 - LT, RH- Hydraulic Clutch Diagnostic & Service Information
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Figure 1. Incorrect Master Cylinder Supply Hose Routing
Item 1: P-trap
Item 2: Master Cylinder Inlet level
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
Hand Operated Vacuum Pump Tester
ZTSE2499
Solo Clutch Resetting Tool
RR1005CL
Clutch Measurement Tool
RR1007CL
Comments
Instructions
Vacuum Bleed Procedure
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IK1100032 - LT, RH- Hydraulic Clutch Diagnostic & Service Information
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SERVICE PARTS INFORMATION
Kit Description
Part Number
Quantity
Required
CYLINDER, CLUTCH OPERAT,
3868300C94
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
1696027C1
4
M6
WASHERS, FLAT METRIC
Notes
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.
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IK1100032 - LT, RH- Hydraulic Clutch Diagnostic & Service Information
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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
If symptoms above are present:
#1
Decision
Continue to Step 2.
1. Perform re-routing procedure (Repair Steps Below)
2. Perform clutch bleeding procedure outlined (Bleed Procedure
Below)
Step Action
DIAGNOSTIC:
Decision
Yes. Continue to Step 3.
Depress the pedal by hand until the master cylinder begins to stroke.
Is clutch pedal free-play between 0.4" and 0.6"?
No. Adjust Clutch Linkage to obtain
0.4" - 0.6" freeplay, continue to step
3
#2
Step Action
DIAGNOSTIC:
Measure release bearing gap using clutch measurement tool
(RR1007CL), long handle bore micrometer, or inside digital spring
#3 caliper.
• See page 8, step 3 of Eaton Manual for reference, if needed.
Decision
Yes. Continue to Step 4.
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:
#4
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" feeler gauge.
No. Replace master cylinder &
slave cylinder then repeat steps 1-4
See page 9 of Eaton Manual for reference, if needed.
Is clutch brake squeeze ~1" from the floor?
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REPAIR STEP(s)
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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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. Seal holes with RTV
4. Using 2 bolts, 2 nuts, 4 washers and 2 p-clamps secure the master supply hose to the cowl tray.
Air Assist Servo Supply Hose Routing
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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).
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Figure 5. Correct air assist servo Cylinder Supply Hose Routing
Item 1: Air line routed over transmission cooler lines
Item 2: Saddle clamp
Item 3: Extension Brake Repositioned
3. Re-position the extension 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
1. Pull vehicle into the shop, apply parking brake, chock wheel and open hood.
2. Drain air tanks.
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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.
6. Set container full of brake fluid on the cowl to allow gravity feed.
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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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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
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Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.
Standard Repair Time(s)
Description
Chassis
SRT
Hours
Reroute hose
LT
T-Time
0.5 HRS
Standard Repair Time(s):
Refer to the SRT Manual for Repair Times
OTHER RESOURCES
Master Service Information Site
Hide Details
Feedback Information
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Staff
ID
Client
ID
Comments
Created
Date
You received the following feedback From: dy35478 - Steve Ziegler Email Address: [email protected]
3/14/2019
DY35478 Job Classification: SA003, Salesperson Dealer: SELKING INTERNATIONAL Feedback: Shouldn't step 18 in the bleed
10:36:20 AM
procedure say to go back to step 2 in step based diagnostics?
Copyright © 2019 Navistar, Inc.
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TSB/Document ID: IK1100032
Replacement Service Bulletin Number:
MFR Communication Date: 2019-03-14
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