Clutches Chevrolet Cab & Chassis K3500

DESCRIPTION

The hydraulic clutch consists of a clutch plate, pressure plate and pilot bearing. Hydraulic clutch has a master cylinder with a reservoir. Clutch pedal moves master cylinder push rod, and a slave (actuator) cylinder at bellhousing moves clutch fork and release bearing. (Scheme 1)

Hydraulic clutch system provides automatic clutch adjustment. No adjustment of clutch linkage or pedal position is required.

Scheme 1

"C" and "K" series vehicles are equipped with a master cylinder, hydraulic line and actuator cylinder assembly which is furnished pre-filled with fluid and pre-bled. (Scheme 2)

No service is possible to individual components of master cylinder assembly or actuator cylinder assembly. Complete cylinder units must be installed when servicing hydraulic clutch.

Scheme 2

TRANSMISSION APPLICATION

RECOMMENDED FLUID

TRANSMISSION LUBRICATION FLUID

ADJUSTMENTS

The hydraulic clutch system provides automatic adjustment; no manual adjustments are necessary.

BLEEDING HYDRAULIC CLUTCH SYSTEM

Note. DO NOT reuse fluid that has been bled from system.

1. Disconnect master cylinder pushrod from clutch pedal. Remove actuator cylinder from clutch housing. First clean and then remove reservoir cap.
2. Slowly depress actuator cylinder pushrod to bottom of bore. While holding actuator pushrod, fill reservoir with NEW DOT 3 brake fluid. Slowly release actuator cylinder pushrod.
3. Hold actuator cylinder vertically with pushrod end facing down. With actuator cylinder lower than master cylinder, hold pushrod against palm of hand. Depress pushrod into actuator cylinder bore with short strokes of 5-10 mm while watching reservoir for air bubbles. Stroke actuator cylinder in this manner until no air bubbles enter reservoir.
4. Reinstall actuator cylinder. Check and fill reservoir with NEW DOT 3 fluid (if necessary). Clean and install reservoir cap. Attach master cylinder pushrod to clutch pedal.

CHECKING HYDRAULIC CLUTCH SYSTEM

Clutch hydraulic system malfunctions can be verified by measuring travel of clutch slave cylinder push rod. On "C" and "K" Series Blazer and Pickup, Sierra, Suburban and Yukon, slave cylinder push rod travel at clutch fork should be at least 1" (25.4 mm) with clutch pedal depressed fully.

If slave cylinder push rod travel is not as specified, check fluid reservoir level. If fluid level is low, check hoses for cracks, wear or other damage. Check hydraulic cylinders for loose mounting and signs of leakage. Fill reservoir with fluid. See RECOMMENDED FLUID under LUBRICATION. If necessary, bleed hydraulic system. Refer to BLEEDING HYDRAULIC CLUTCH SYSTEM . Replace clutch hydraulic system if fluid leakage is excessive.

REMOVAL & INSTALLATION

Removal (BW-4401, BW-4470 & NP-241)

1. Disconnect negative battery cable. Place transfer case in 4H position. Raise and support vehicle. Remove skid plate (if equipped). Drain fluid from transfer case. Mark front output shaft yoke and drive shaft for reassembly reference. Remove front drive shaft. Remove left strut rod. Mark rear output shaft yoke and drive shaft for reassembly reference. Remove rear drive shaft.
2. Disconnect electrical connectors from transfer case. Disconnect shift rod from transfer case. Support transfer case with jack. Remove transfer case-to-transmission mount bolts and spring washers (if equipped). Slide transfer case rearward until free of transmission output shaft. Lower and remove transfer case. Remove and discard gasket.

Installation

To install, reverse removal procedure. Tighten transfer case-to-transmission mount bolts to 24 ft. lbs. (33 N.m). Fill transfer case with fluid. See RECOMMENDED FLUID under LUBRICATION.

Removal

1. Disconnect negative battery cable. Remove shift lever retainer screws and retainer. Remove shift lever boot mounting screws and boot. Remove shift lever insulator. Remove shift lever. Raise and support vehicle. Drain transmission fluid.
2. Mark drive shaft for reassembly reference. Remove drive shaft. Remove transfer case (if equipped). Remove parking brake and cable (if equipped). Disconnect electrical connectors. Remove clutch slave cylinder. Support transmission.
3. Remove exhaust pipes, crossmember and other components as necessary for clearance. Remove dust cover bolts and dust cover (if equipped). Remove transmission mounting bolts. Pull transmission straight back on clutch hub splines, and remove transmission.

To install, shift transmission into Neutral, and reverse removal procedure. Lightly coat input shaft splines with high-temperature grease. Tighten bolts to specifications. Refer to the TORQUE SPECIFICATIONS table. Fill transmission with fluid. See RECOMMENDED FLUID under LUBRICATION.

CLUTCH ASSEMBLY & PILOT BEARING

1. Remove transmission. See «TRANSMISSION»(/chevrolet/cab-chassis-k3500/1989-2000/remont/clutches-manual-hydraulic/#clutches). Remove slave cylinder from bellhousing. (Scheme 1) Remove bellhousing bolts and remove bellhousing.
2. Remove flywheel cover bolts and remove flywheel cover. Remove clutch fork spring, seat, clutch fork and release bearing. Remove ball stud. Install Clutch Aligner (J-5824-01) to support clutch plate. Mark flywheel and pressure plate for reassembly reference.
3. Evenly loosen pressure plate bolts 1-2 turns at a time until pressure plate spring tension is released. Remove clutch plate and pressure plate. Remove clutch aligner. Remove pilot bearing if worn or damaged using Pilot Bearing Puller (J-23907).

Inspection

1. Clean all components with water-dampened cloth to remove asbestos fibers. Clean clutch fork, bellhousing and ball stud with solvent. Release bearing is permanently packed with lubricant and should not be cleaned with solvent.
2. Inspect all components for wear or damage. Inspect all contact surfaces for scoring, warping and damage. Clutch plate runout must not exceed .20" (5.08 mm). Inspect friction surfaces for excessive oil. Inspect splines for nicks, burrs and sliding fit. Bellhousing transmission pilot hole runout should not exceed .015" (.38 mm).

1. On 4.3L, 5.0L and 5.7L, use brass drift to install NEW pilot bearing into flywheel, if removed. On 6.5L diesel, use Pilot Bearing Driver (J-34140) to install NEW pilot bearing into flywheel, if removed. On 4.3L, 5.0L and 5.7L, lubricate pilot bearing with machine oil. On 6.5L diesel, pilot bearing is sealed and does not require lubrication. (Scheme 1)
2. Install Clutch Aligner (J-5824-01) to support clutch plate. Install clutch plate and pressure plate to flywheel. Ensure reference marks are aligned. Install and tighten NEW spring washers and bolts evenly to avoid distortion. Remove clutch aligner.
3. Lubricate ball stud and clutch fork fingers with high-temperature grease. Lubricate O.D. groove and pack grease into I.D. recess of release bearing. Install ball stud, clutch fork, seat, clutch fork spring and release bearing. (Scheme 1) To complete installation, reverse removal procedure. Tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(/chevrolet/cab-chassis-k3500/1989-2000/remont/clutches-manual-hydraulic/#clutches). Fill reservoir with fluid. See «RECOMMENDED FLUID»(/chevrolet/cab-chassis-k3500/1989-2000/remont/clutches-manual-hydraulic/#clutches__recommended-fluid) under LUBRICATION. Bleed hydraulic system. Refer to «BLEEDING HYDRAULIC CLUTCH SYSTEM»(/chevrolet/cab-chassis-k3500/1989-2000/remont/clutches-manual-hydraulic/#clutches__bleeding-hydraulic-clutch-system) under IN-VEHICLE SERVICE.

1. Disconnect negative battery cable. Remove steering column lower cover or panel (if needed). Remove A/C duct from lower left side of instrument panel as necessary. Separate push rod from clutch pedal.
2. Remove master cylinder-to-cowl panel nuts. Pull clip retaining clutch actuator hose from its bolt. NOTE: If assembly is being replaced, it may be necessary to cut the line at rear of engine to ease removal of assembly.
3. Raise and support vehicle. Remove actuator cylinder-to-clutch housing nuts. Remove hydraulic line-to-engine nuts and clips. Remove hydraulic clutch assembly. Remove inspection plug. To install, reverse removal procedure. Tighten nuts to specifications. Refer to the «TORQUE SPECIFICATIONS»(/chevrolet/cab-chassis-k3500/1989-2000/remont/clutches-manual-hydraulic/#clutches) table. Fill reservoir with NEW DOT 3 fluid. Bleed system. See «BLEEDING HYDRAULIC CLUTCH SYSTEM»(/chevrolet/cab-chassis-k3500/1989-2000/remont/clutches-manual-hydraulic/#clutches__bleeding-hydraulic-clutch-system) under IN-VEHICLE SERVICE.

See MASTER CYLINDER & RESERVOIR.

OVERHAUL

Note. All master and slave (actuator) cylinders are serviced as an assembly. Rebuilding or overhaul is not possible.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• COMPUTER RELEARN PROCEDURES
• RECOMMENDED FLUID
• BLEEDING HYDRAULIC CLUTCH SYSTEM
• TORQUE SPECIFICATIONS