Freightliner Business Class M2. Instruction - page 10

25–02 Eaton Fuller Clutch

Release Cross-Shaft
Lubricating

IMPORTANT: This maintenance operation per-
tains only to vehicles equipped with mechanical
(not hydraulic) linkages.

The clutch release cross-shaft is equipped with two
grease fittings in the transmission clutch housing.
See

Fig. 3

and

Fig. 4

. Wipe the dirt from the grease

fittings and lubricate with multipurpose chassis
grease.

25–03 Clutch Hydraulic Fluid

Level Checking

WARNING

Use only approved clutch hydraulic fluid (DOT 4
brake fluid) in the clutch hydraulic system. Do not
mix different types of brake fluid. The wrong fluid
will damage the rubber parts of the system, caus-
ing loss of clutch function and the risk of serious
personal injury.

CAUTION

Do not allow the fluid level in the reservoir to go
below the MIN line. If too much air enters, the hy-
draulic system will not operate correctly, and the
clutch could be damaged.

If the fluid level is below the MIN line, fill the reser-
voir with DOT 4 brake fluid until the level reaches the
MAX line. See

Fig. 5

.

25–04 Clutch Hydraulic Fluid

Changing

Replace the clutch hydraulic fluid every two years to
ensure clutch function is reliable and correct. Use the

f250048a

1

2

10/19/93

1.

Clutch Release Cross-Shaft

2.

Grease Fitting

Fig. 3, Cross-Shaft Grease Fitting, Left Side

f260146a

05/27/93

Fig. 4, Cross-Shaft Grease Fitting, Right Side

12/10/2001

1

2

3

4

5

6

f250580

1.

Reservoir Cap

2.

Reservoir

3.

Pedal Unit

4.

Master Cylinder

5.

Hydraulic Hose

6.

Slave Cylinder

Fig. 5, Clutch Components

Clutch

25

Business Class M2 Maintenance Manual, August 2015

25/2

procedures below. Fluid replacement must be done
at an authorized Freightliner service facility.

Flushing

1.

Shut down the engine.

2.

Apply the parking brakes, chock the front and
rear tires, and raise the hood.

WARNING

Clutch hydraulic fluid (DOT 4 brake fluid) is haz-
ardous. It may be a skin irritant and can cause
blindness if it gets in your eyes. Always wear
safety glasses when handling clutch hydraulic
fluid or bleeding hydraulic lines. If you get clutch
hydraulic fluid on your skin, wash it off as soon
as possible.

3.

Prepare the pressure bleeding equipment ac-
cording to the manufacturer’s instructions. Use
DOT 4 brake fluid. Pressurize the bleed adaptor
to 15 psi (103 kPa).

CAUTION

Do not spill clutch hydraulic fluid (DOT 4 brake
fluid) on the cab paint. Clean it off immediately if
any is spilled. DOT 4 brake fluid can damage
paint.

4.

Remove the reservoir lid and install the pressure
bleed adaptor on the reservoir.

5.

Pressurize the reservoir, filling the system. Open
the bleed valve on the bleed tank of the adaptor.

NOTE: A pressure bleeder hose (J-29532) and
a bleed adaptor (J-35798) for the fluid reservoir
are available through SPX Kent-Moore Tools
and may be used to complete the following pro-
cedure. To order these parts, call Kent-Moore at
1-800-328-6657.

6.

Flush the hydraulic system. See

Fig. 6

.

6.1

Open the bleed screw on the slave cylin-
der.

6.2

Using a drain pan or other suitable con-
tainer, collect the fluid that drains from the
slave cylinder bleed valve, at least 0.5
quarts (0.5 liters).

6.3

When all the old fluid has passed through
the system and only new, clean fluid is
coming out, close the bleed screw.

7.

Check the fluid level in the reservoir and bleed
the system according to the procedures under
the heading "Bleeding the Clutch." See

Fig. 7

.

Bleeding the Clutch

1.

Remove the cap from the bleed valve. Install a
transparent drain hose on the bleed valve of the
slave cylinder.

2.

Open the slave cylinder bleed screw. Observe
the flow of clutch hydraulic fluid through the drain
hose. When bubbles no longer appear in the
fluid, close the slave cylinder bleed screw.

3.

Disconnect the transparent hose. Tighten the
bleed screw 88 lbf·in (1000 N·cm) and install the
cap on the slave cylinder bleed valve.

4.

Close the valve on the bleed tank of the pres-
sure bleed adaptor. Remove the pressure bleed
adaptor.

5.

Check the fluid level in the reservoir. If neces-
sary, add or remove clutch hydraulic fluid to bring
the fluid level to the MAX line. Install the reser-
voir lid.

CAUTION

When removing fluid from the reservoir, use a
clean tool that is used only for brake fluid. Using
a tool contaminated with oil or chemical residue
will destroy hydraulic system parts and cause the
system to malfunction.

6.

Depress the clutch pedal a few times. There
should be resistance over the full pedal stroke.

7.

Check the entire system for leaks. Tighten the
connections between the components if neces-
sary. Check the fluid level in the reservoir again.

8.

Make sure the reservoir lid is tight.

9.

Lower the hood and remove the chocks from the
front and rear tires.

Clutch

25

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25/3

12/11/2001

f250582

1

2
3

4

5

6

7

8

9

10

1

2
3

1.

Clamp-Mounting Bolt, 1/4–20

2.

Plated Steel Washer

3.

Locknut, 1/4–20

4.

Bell Housing Standoff Bracket

5.

Slave Cylinder Standoff Bracket

6.

Hydraulic Hose

7.

Slave Cylinder

8.

Bleed Valve

9.

Bell Housing

10. Slave Cylinder Mounting Capscrew, M8

Fig. 6, Clutch Slave Cylinder

Clutch

25

Business Class M2 Maintenance Manual, August 2015

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25–05 Clutch Adjusting,

Manually Adjusted
Clutches

NOTE: This procedure is only required for ve-
hicles equipped with non-synchronized transmis-
sions and manually adjusted clutches.

Release bearing travel is the clearance between the
rear surface of the release bearing housing and the
forward surface of the clutch brake disc. This dis-
tance must be maintained between 1/2 and 9/16 inch
(12.7 and 14.3 mm).

1.

Remove the clutch inspection cover from the bell
housing. See

Fig. 8

.

1

2

3

4

5

6

7

8

9

12/11/2001

f250581

1.

M8 Capscrew and Washer

2.

Pedal Unit Mounting Plate

3.

Reservoir

4.

Pedal Unit

5.

Master Cylinder

6.

Hydraulic Hose

7.

Cup Bracket

8.

Standoff Bracket

9.

Mounting Bolt, M10

Fig. 7, Clutch Master Cylinder

Clutch

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