IK1100025 - Prostar and Lonestar Clutch Service Information

Countries:
Availability:

Page 1 of 3

CANADA,
Document
UNITED STATES ID:
ISIS, FleetISIS,
Revision:
Body Builder

IK1100025
1

Major System: CLUTCH

Created:

11/5/2012

Current
Language:
Other
Languages:

English

Last
Modified:

3/20/2013

NONE

Author:

Matthew
Boyer

Viewed:

327
Less Info

Coding Information

Hide Details

Copy Link

Copy Relative
Link

Bookmark

Add to
Favorites

Print

Provide
Feedback

View My
Bookmarks

Helpful

Not Helpful

3

2

Title: Prostar and Lonestar Clutch Service Information
Applies To: International Prostars and Lonestars Built with Hydraulic Clutch
Systems

DESCRIPTION
This iKNow document is designed to outline the specific clutch service procedures unique to
Prostar and Lonestar trucks equipped with Hydraulic clutch release systems.

MASTER AND SLAVE CYLINDERS
Prostars and Lonestars equipped with hydraulic clutch release systems utilize Meritor built
master and slave cylinders. They are fully supported by Meritor Wabco, so any failures that
are found need to have an Ontrac case file started for warranty coverage. The common
failure modes are a vehicle creeping from a stationary position with the pedal fully
depressed, or a pedal with light or no resistance to it.
Master Cylinder Replacement Procedure
Slave Cylinder Replacement Procedure
NOTE:

Meritor WABCO requires pre-authorization for all repairs over $125. For any repairs above
that amount, you must contact Ontrac at 1-800-535-5560 prior to making the repair. For

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 4/1/2013

IK1100025 - Prostar and Lonestar Clutch Service Information

Page 2 of 3

further information look at warranty policy letter 05-003G and 04-004G

CLUTCH FLUID AND RESERVOIR
All Prostars and Lonestars equipped with Hydraulic clutches use DOT 3 or DOT 4 fluid.
The system holds 16.6 ounces of fluid. During inspection of a unit in for service, the clutch
reservoir needs to be inspected for mounting and condition of the fluid. The reservoir caps
should be removed and the rubber grommets need to be checked for swelling or damage.
Swelling could be a sign of fluid contamination. Also, the reservoir should be level, full and
securely mounted. The reservoir is located near the cowl on the left side of the truck.

CLUTCH BLEEDING PROCEDURE
There a two different clutch bleeding procedures. The reverse bleeding procedure is
preferred in which you use a pressure bleeder to remove the air from the bottom up. Here
is a link to the procedure.
Reverse Pressure Bleeding Procedure
If the reverse bleeding procedure cannot be performed, the vehicle can be pressure bleed
from the top down. This process may take longer, as you must stop and refill the reservoir
to maintain the brake fluid above the min level. Here is a link to the procedure.
Pressure Bleeding Procedure

CLUTCH ADJUSTMENT
Before condemning the clutch, the clutch must be adjusted properly. The distance between
the release bearing and the clutch brake must be 0.490" to 0.560". If a clutch is replaced
and found to be adjustable, and not within this specification, the clutch replacement may be
deemed not warrantable.
There are 3 different clutches that are commonly factory installed on these vehicles. The
Eaton Solo clutch is a self adjusting clutch that maintains constant release bearing position.
For initial set up, please see the attached manual starting at page 8. For resetting the wear
indicator or release bearing position with the clutch in the chassis, please see page 14. If you
cannot get the cam to move, it may be necessary to loosen the transmission and install 1/2
inch spacers between the bellhousing and the engine to get enough pull on the bearing to
reset the clutch.

Solo manual

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 4/1/2013

IK1100025 - Prostar and Lonestar Clutch Service Information

Page 3 of 3

The Eaton Easy Pedal clutches are manual adjusting clutches that are installed in Prostars
and Lonestars. For adjustment procedures for these clutches, see the attached manual
starting at page 18.

Easy pedal manual
Easy Pedal Adjustment Interval With Hydraulic Clutch Linkage
For the ZF Sachs clutches, please click the iKNow link attached below.
IK1100020 ZF Sachs Twin XTend clutch

LINKAGE ADJUSTMENT
IK1100021 Hydraulic Clutch Adjustment for ProStar + Vehicles

ADDITIONAL RESOURCES
IK1100005 Eaton Roller Fork Identification
IK1100004 Clutch Linkage Rattle in Transtar, Prostar, and Lonestar Truck (20072009 Mechanical Linkage)

Feedback Information

Hide Details

Viewed:

326

Helpful:

3

Not Helpful: 2

Staff
ID

Client
ID
U00MSE1

Comments
You received the following feedback From: U00MSE1 - Mark Ehlers Email Address: SMTP:
{mark.ehlers@navistar.com}mark.ehlers@navistar.com Job Classification: AD001,
Administration Dealer: Field Personnel Feedback: can you please request translation into
Russian?

Created
Date
3/21/2013
1:13:21 PM

Copyright © 2013 Navistar, Inc.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 4/1/2013