11/30/22, 12:38 PM

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Automated Manual Transmission (AMT)
Concentric Clutch Actuator (CCA), Diagnostic
guidance for P107538

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Internal Content

SISTER SOLUTION:

K63231010

CREATED BY:
UT9268H
CREATED:
Jun 22, 2018, 06:04PM
LAST CHANGED BY:
RU4469V
LAST CHANGED:
Jul 30, 2019, 04:14PM
REVIEWER:
ut9268h
NEXT REVIEW:
Jun 21, 2019, 10:00PM

Fault Tracing Requirements and Criteria
• If the vehicle does not have P107538 logged in the TECU, the CCA and
clutch system is not leaking air and should not be investigated.
• If there is not a logged fault P107538 in the TECU then the history of the
truck should be checked in the Product History Viewer to see if there is a
past history of the faults. If the truck has never logged these faults or the
faults that have been logged are very old (>12 months) then any diagnostic
and subsequent replacement of the CCA or other components may be
denied by Warranty.
- Note: Dealer service managers and warranty administrators should
have access to the PHV. If there are more persons that need access
to the PHV to evaluate the histories for this fault please contact your
Dealer Service Administrator (DSA) for access.
• If the P107538 fault is Active or has very high occurrences of inactive
faults—a minimum of 5 times in the last 6 months AND a minimum of 1
time in the last month—in the recent or current history of the truck, the
steps in the Pre-Removal Inspection section below should be followed.
- If the P107538 faults have been logged in the TECU at a lower
frequency than described above, and this is the reason for the
workshop visit, inform the customer that a few singular cases of
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this DTC may be triggered as described in the DTC Descriptions
section below

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section below.

Pre-Removal Inspection
IMPORTANT
If P107538 is found to meet the requirements for CCA Replacement
while working on another customer complaint with the gearbox that
would require a short REMAN gearbox replacement then a CCA
replacement is not required since the short REMAN includes the CCA.

1. Use Premium Tech Tool (PTT) Operation 4111-08-03-02 Clutch Wear
Check, Test to establish a baseline for the current wear limits and life of the
clutch prior to disassembly and fault tracing of the unit.
In cases where the clutch assembly is out of warranty this information
is useful for informing the customer if the clutch is close to its wear
limits.

2. Does the vehicle meet any of the items from the Requirements and
Criteria section above?
No: Then the CCA is not leaking and should not be fault traced for
an air leak. Use the Mechanical Evaluation section to determine if
the CCA needs to be replaced.
Yes: Replace the CCA, air line and CVU.
While the gearbox is out of the chassis evaluate the unit
for:
Loss of input shaft preload
Use CBR-565 for input shaft repairs.
Input shaft play on crawler gearboxes is normal.
Oil, coolant or other air leaks and repair as needed.
3. Check for proper assembly and calibration prior to reinstalling
the gearbox in the vehicle. Road test and verify the repair.

DTC Descriptions
• P107538 (MID 130 PSID 27 FMI 8) - This fault code indicates that the
clutch control is compromised, and the TECU SW is taking mitigating actions
to manage the issue which could reduce comfort during take-off. The TECU
is commanding the clutch to move using the CVU and the clutch is moving
Live
UI than expected to the demanded position. The control command to
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the CVU exceeds a set PWM and the fault will log. This is normally found
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during ‘Idle Drive ‘events when the vehicle is being pulled along on the idle
governor in gear 1-6 or reverse. This can also happen during shifting events
when the clutch is commanded to disengage for an up or down shift and the
clutch position does not meet the demand within a set amount of time.
Singular events of this DTC may be triggered due to low air pressure, low
ambient temperature or intermittent dynamic conditions in the pneumatic
system. In these situations, the DTC will become inactive when the driver
selects N during standstill and the TECU SW will then revert back to normal
operation.
• P107575 (MID 130 PSID 27 FMI 14) - Clutch cannot disengage. This fault
can be logged when stationary or moving. If the TECU determines that the
clutch is not responding to the disengage command. This fault code will be
active. The red stop engine lamp will be lit when this happens. If the unit
logs this fault when unit is stopped and in neutral because the clutch does
not respond to the disengage command the engine will not automatically
shut down.
• P107594 (MID 130 PSID 27 FMI 0) - This fault indicates an unintentional
disengagement of the clutch. The wear in the CCA allows movement of the
CCA body and the clutch position sensor picks up this movement and can
believe the clutch is disengaging without being commanded to do so. If this
fault is the only one logged, then the CVU could be leaking air into the CCA
after the clutch is engaged and all valves are turned off.
• P106074 - This fault indicates that the driver is using the accelerator to
hold the vehicle on a hill rather than applying the service brakes. Not a valid
fault to cause a replacement of the CCA.
• P106063 - This fault indicates improper gear selection and starting
conditions based on load. Not a valid fault to cause a replacement of the
CCA.

Mechanical Evaluation
IMPORTANT
The test procedure of pushing the CCA back and plugging the CVU and
walking away from the unit for 30 minutes or more to check for a leak is
NOT a valid test and should NOT be used for checking for leaks of the
system. The design of the CVU will allow the internal spring force of the
CCA to suck air through the CVU if there is no air pressure being
supplied to the CVU.

UI
1. Check
the face of the CCA bearing for wear.
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• The example below shows a bearing face with normal wear, caused
by the movement between the clutch fingers and the bearing face.

• CCAs with wear greater than shown above do not cause a
functional issue. The bearing should be reused if nothing else is
found wrong.

2. Check for Heat Damage
• A CCA that has had a clutch failure with extreme heat should be
inspected. A melted, extremely worn or missing dust boot should be
replaced.

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• A CCA that passes all of the evaluations but has a melted position
sensor can be reused and the sensor replaced separately. An
example is shown below:

3. Check for physical damage to the CCA
• Check the outer dust skirt as shown in the picture below. If the outer
dust skirt is out of place, replace the CCA.

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• Check the position sensor: If there is physical damage to the sensor
only, it can be repaired with a sensor without replacing the CCA if the
CCA itself is in good condition.

For more information refer to the below Navigator training modules:
500583: Mack CCA Diagnostics
500559: Volvo CCA Diagnostics

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