Clutches GMC Jimmy Typhoon

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 cylinder at the bell-housing moves the clutch fork and release bearing. (Scheme 1)

TRANSMISSION APPLICATION

RECOMMENDED FLUID

RECOMMENDED 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.

With Bleeder Screw

1. Fill reservoir with clean DOT 3 brake fluid. Disconnect slave cylinder from bellhousing, leaving line attached. Hold slave cylinder at 45-degree angle with bleeder screw facing upward.
2. Have an assistant depress clutch pedal while opening bleeder screw. Close bleeder screw and release pedal. Repeat sequence until all air is removed from system. Ensure master cylinder reservoir stays full during bleeding process. Install slave cylinder.

Without Bleeder Screw

1. Separate master cylinder push rod from clutch pedal. Disconnect slave cylinder from bellhousing, leaving line attached. Remove reservoir cap. Slowly depress slave cylinder push rod to bottom of cylinder bore. Hold slave cylinder push rod, and fill reservoir with clean DOT 3 brake fluid. Slowly release slave cylinder push rod.
2. Hold slave cylinder vertically with push rod end facing the ground. Hold slave cylinder push rod against palm of hand and position lower than master cylinder. Depress slave cylinder push rod into cylinder bore with short strokes while observing reservoir for air bubbles.
3. Repeat sequence until air bubbles are not longer present in reservoir fluid. Ensure master cylinder reservoir stays full during bleeding process. Install slave cylinder. Install reservoir cap. Re-attach master cylinder push rod 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 pressed fully to floor stop.

On "S" and "T" Series Blazer and Pickup, Jimmy and Sonoma, slave cylinder push rod travel at clutch fork should be at least .75" (19 mm) with clutch pedal pressed fully to floor stop.

On Commercial Van, slave cylinder push rod travel at clutch fork should be at least 1.338" (34 mm) with clutch pedal pressed fully to floor stop. If slave cylinder push rod travel is not as specified, check reservoir fluid 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. Refer to RECOMMENDED FLUID table under LUBRICATION. If necessary, bleed hydraulic system. See BLEEDING HYDRAULIC CLUTCH SYSTEM . Repair or replace clutch hydraulic system if fluid leakage is excessive.

REMOVAL & INSTALLATION

Removal (BW-4401, BW-4470 & NP-241, "K" Series Blazer & Pickup, Sierra, Suburban & Yukon)

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 (BW-4401, BW-4470 & NP-241, "K" Series Blazer & Pickup, Sierra, Suburban & Yukon)

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 table under LUBRICATION.

Removal (NP-231 & NP-233 "T" Series Blazer & Pickup, Jimmy & Sonoma)

2) Disconnect vacuum lines and electrical connectors from transfer case (if equipped). Disconnect shift rod from transfer case. Support transfer case with jack. Remove transfer case-to-transmission mount bolts. Slide transfer case rearward until free of transmission output shaft. Lower and remove transfer case. Remove and discard gasket.

Installation (NP-231 & NP-233 "T" Series Blazer & Pickup, Jimmy & Sonoma)

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 table under LUBRICATION.

Removal ("C" & "K" Series Blazer & Pickup, Sierra, Suburban & Yukon)

2) Mark drive shaft for reassembly reference. Remove drive shaft. Carefully 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.

Installation ("C" & "K" Series Blazer & Pickup, Sierra, Suburban & Yukon)

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 SPECS ("C/K" BLAZER & PICKUP, SIERRA, SUBURBAN & YUKON) table. Fill transmission with fluid. Refer to the RECOMMENDED FLUID table under LUBRICATION.

Removal ("S" & "T" Series Blazer & Pickup, Jimmy & Sonoma)

1. Disconnect battery negative cable. Shift transmission into Neutral. Remove shift lever knob and nut. Remove shift lever retainer screws and retainer (if equipped). Remove shift lever boot mounting screws and boot. Remove shift lever and nut.
2. Raise and support vehicle. Drain transmission fluid. Remove parking brake cable for clearance. Mark drive shaft for reassembly reference. Remove drive shaft. Remove skid plate (if equipped). Carefully remove transfer case (if equipped).
3. Disconnect electrical connectors. On 4.3L models, purge fuel system, and disconnect fuel lines at manifold. On all models, disconnect exhaust pipe. Remove clutch slave cylinder. Support transmission. Remove transmission mounting bolts as necessary. Remove catalytic converter hanger. Remove support braces. Remove crossmember. Remove transmission mounting bolts.
4. On 4.3L models, rotate transmission counterclockwise, then pull transmission straight back on clutch hub splines, and remove transmission. On 2.5L and 2.8L models, pull transmission straight back on clutch hub splines, and remove transmission.

Installation ("S" & "T" Series Blazer & Pickup, Jimmy & Sonoma)

1. To install, shift transmission into High gear, and reverse removal procedure. Lightly coat input shaft splines with high-temperature grease. On 4.3L models, rotate transmission clockwise onto clutch hub splines.
2. Before installing the shift lever, shift the transmission into Neutral gear. Tighten bolts to specifications. Refer to the «TORQUE SPECS ("S/T" SERIES BLAZER & PICKUP, JIMMY & SONOMA)»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table. Fill transmission with fluid. See the «RECOMMENDED FLUID»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table under LUBRICATION.

Removal (Commercial Van)

1. Disconnect battery negative cable. Remove shift lever knob and nut. Remove shift lever boot. To remove shift lever, push down and turn shift lever retainer counterclockwise. Remove shift lever. Raise and support vehicle. Drain transmission fluid.
2. Mark drive shaft for reassembly reference. Remove drive shaft. Remove parking brake and cable (if equipped). Remove electrical harness bracket bolt. Disconnect electrical connectors. Support transmission.
3. Remove exhaust pipe and other components as necessary for clearance. Remove transmission mounting bolts and washers. Pull transmission straight back on clutch hub splines, and remove transmission.

Installation (Commercial Van)

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 SPECS (COMMERCIAL VAN) table. Fill transmission with fluid. See the RECOMMENDED FLUID table under LUBRICATION.

CLUTCH ASSEMBLY & PILOT BEARING

Note. DO NOT use compressor air to clean clutch parts. The clutch plate contains asbestos which is harmful if inhaled.

1. Remove transmission. See «TRANSMISSION»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) under REMOVAL & INSTALLATION. 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, clutch plate and pressure plate for reassembly reference.
3. Evenly loosen pressure plate bolts 1-2 turns at a time until clutch 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 ("C" & "K" Series Blazer & Pickup, Sierra, Suburban & Yukon)

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 be greater than .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 be greater than .015" (.38 mm).

1. On 4.3L, 5.0L and 5.7L models, use brass drift to install NEW pilot bearing into flywheel, if removed. On 6.2L and 6.5L diesel models, use Pilot Bearing Driver (J-34140) to install NEW pilot bearing into flywheel, if removed. On 4.3L, 5.0L and 5.7L models, lubricate pilot bearing with machine oil. On 6.2L and 6.5L diesel models, 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)
4. To complete clutch assembly installation, reverse removal procedure. Tighten all retaining bolts to specifications. Refer to the «TORQUE SPECS ("C/K" BLAZER & PICKUP, SIERRA, SUBURBAN & YUKON)»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table. Fill reservoir with fluid. See «RECOMMENDED FLUID»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table under LUBRICATION. Bleed system. See «BLEEDING HYDRAULIC CLUTCH SYSTEM»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches__bleeding-hydraulic-clutch-system) under IN-VEHICLE SERVICE.

1. Remove transmission. See «TRANSMISSION»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) under REMOVAL & INSTALLATION. 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 and release bearing. Remove ball stud from clutch fork. Remove retainer from clutch fork if worn or damage. Install Clutch Aligner (J-33169) to support clutch plate. Mark flywheel, clutch plate and pressure plate for reassembly reference.
3. Evenly loosen pressure plate bolts 1-2 turns at a time until clutch 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 ("S" & "T" Series Blazer & Pickup, Jimmy & Sonoma)

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 be greater than .20" (5.08 mm). Inspect friction surfaces for excessive oil. Inspect splines for nicks, burrs and sliding fit.

1. Use Pilot Bearing Driver (J-1522) to install NEW pilot bearing into flywheel, if removed. (Scheme 1) Lubricate pilot bearing with machine oil. Install Clutch Aligner (J-33169) to support clutch plate. Install clutch plate and pressure plate to flywheel. Ensure reference marks are aligned.
2. Install and tighten NEW spring washers and bolts evenly to avoid distortion. Remove clutch aligner. 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.
3. If replacing clutch fork retainer, install retainer so fingers and tabs fit into release bearing groove, and retainer wraps around flat side of ball stud. Install ball stud, clutch fork, retainer and release bearing. (Scheme 1)
4. To complete clutch assembly installation, reverse removal procedure. Tighten all retaining bolts to specifications. Refer to the «TORQUE SPECS ("S/T" SERIES BLAZER & PICKUP, JIMMY & SONOMA)»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table. Fill reservoir with fluid. See «RECOMMENDED FLUID»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table under LUBRICATION. Bleed system. See «BLEEDING HYDRAULIC CLUTCH SYSTEM»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches__bleeding-hydraulic-clutch-system).

1. Remove transmission. See «TRANSMISSION»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) under REMOVAL & INSTALLATION. 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 and release bearing. Remove ball stud. Install Clutch Aligner (J-5824-01) to support clutch plate. Mark flywheel, clutch plate and pressure plate for reassembly reference.
3. Evenly loosen pressure plate bolts 1-2 turns at a time until clutch plate spring tension is released. Remove clutch plate and pressure plate. Remove clutch aligner. Remove pilot bearing if worn or damaged; use Pilot Bearing Puller (J-23907) on 4.3L, 5.7L and 7.4L models or Pilot Bearing Puller (J-1448) on 6.2L diesel models.

Inspection (Commercial Van)

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 be greater than .20" (5.08 mm). Inspect friction surfaces for excessive oil. Inspect splines for nicks, burrs and sliding fit.

1. On 4.3L, 5.7L and 7.4L models, use brass drift to install NEW pilot bearing into flywheel, if removed. On 6.2L diesel models, use Pilot Bearing Driver (J-34140) to install NEW pilot bearing into flywheel, if removed. On 4.3L, 5.7L and 7.4L models, lubricate pilot bearing with machine oil. On 6.2L diesel models, 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 and release bearing. (Scheme 1)
4. To complete installation, reverse removal procedure. Tighten bolts to specifications. See «TORQUE SPECS (COMMERCIAL VAN)»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table. Fill reservoir with fluid. See «RECOMMENDED FLUID»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table under LUBRICATION. Bleed system. See «BLEEDING HYDRAULIC CLUTCH SYSTEM»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches__bleeding-hydraulic-clutch-system) under IN-VEHICLE SERVICE.

Scheme 1

1. Disconnect battery negative cable. Remove steering column lower cover or panel. Remove A/C duct from lower left side of instrument panel as necessary. Remove nut retaining push rod to clutch pedal. Separate push rod from clutch pedal.
2. Disconnect slave cylinder hose from master cylinder and plug openings. Remove master cylinder retaining nuts. Remove master cylinder and reservoir assembly. Remove gasket from master cylinder and cowl.

To install master cylinder and reservoir, reverse removal procedure. Install NEW gasket. Tighten nuts to specifications. See the TORQUE SPECS ("C/K" BLAZER & PICKUP, SIERRA, SUBURBAN & YUKON) table. Fill reservoir with fluid. See RECOMMENDED FLUID table under LUBRICATION. Bleed system. See BLEEDING HYDRAULIC CLUTCH SYSTEM under IN-VEHICLE SERVICE.

1. Disconnect battery negative cable. Remove steering column lower cover or panel. Remove A/C duct from lower left side of instrument panel as necessary. Remove cotter pin and washer retaining push rod to clutch pedal. Separate push rod from clutch pedal.
2. Disconnect reservoir hose and slave cylinder hose from master cylinder and plug openings. Remove master cylinder retaining nuts. Remove master cylinder. Remove gasket from master cylinder and cowl. Remove reservoir retaining bolts and remove reservoir.

To install, reverse removal procedure. Install NEW gasket. Tighten all retaining bolts and nuts to specifications. Refer to the TORQUE SPECS ("S/T" SERIES BLAZER & PICKUP, JIMMY & SONOMA) table. Fill reservoir with fluid. See RECOMMENDED FLUID table. Bleed system. See BLEEDING HYDRAULIC CLUTCH SYSTEM under IN-VEHICLE SERVICE.

1. Disconnect battery negative cable. Remove nut retaining push rod to clutch pedal. Separate push rod from clutch pedal. Remove master cylinder retaining nuts. Remove master cylinder reservoir and slave cylinder hose coupling bracket retaining nuts and washers.
2. Separate master cylinder and reservoir assembly hose from coupling and plug openings. Remove master cylinder and reservoir assembly.

1. To install, reverse removal procedure. Difficulty may be experienced in connecting master cylinder reservoir hose to coupling due to internal hydraulic pressure. Ensure push rods are fully retracted to assist in connection of master cylinder reservoir hose to coupling.
2. Tighten all retaining nuts to specification. Refer to the «TORQUE SPECS (COMMERCIAL VAN)»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table. Fill reservoir with fluid. See the «RECOMMENDED FLUID»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches) table under LUBRICATION. Bleed clutch hydraulic system. Refer to «BLEEDING HYDRAULIC CLUTCH SYSTEM»(/gmc/jimmy-typhoon/1992-1993/remont/clutches-manual-hydraulic/#clutches__bleeding-hydraulic-clutch-system) .

Removal

Disconnect battery negative cable. Raise and support vehicle. Disconnect slave cylinder hose from slave cylinder and plug openings. Remove slave cylinder retaining nuts and remove slave cylinder.

Installation

To install, reverse removal procedure. On commercial van, DO NOT remove plastic push rod retainer from slave cylinder. Retainer straps will break when clutch pedal is depressed. Tighten nuts to specifications. See TORQUE SPECIFICATIONS table. Bleed hydraulic system. See BLEEDING HYDRAULIC CLUTCH SYSTEM under IN-VEHICLE SERVICE.

OVERHAUL

Note. Information for Commercial Van not available from manufacturer.

Disassembly & Inspection (Except Commercial Van)

1. Pull out reservoir adapter and adapter seal. Pull back dust cover and remove snap ring from cylinder. (Scheme 2) Remove push rod. Remove plunger and spring assembly.
2. Remove spring from front of plunger. Remove seal support, front seal, shim and back seal from plunger. DO NOT damage plunger surface. Clean all parts with clean brake fluid.
3. Inspect cylinder bore and plunger for scratches, ridges or scoring. Inspect dust cover for wear or damage. Replace master cylinder if damaged.

Reassembly

1. Lubricate NEW seals and cylinder bore with clean brake fluid. Fit NEW back seal into groove in plunger. (Scheme 2) Install shim and NEW front seal on plunger, with flat side against shim. Install seal support and spring.
2. Carefully install plunger assembly into cylinder bore. Depress plunger with push rod, and seat snap ring in groove. Lightly grease inside of dust cover and install. Install NEW adapter seal into master cylinder and press reservoir adapter into place.

Scheme 2

1. Remove push rod and dust cover. (Scheme 3) Remove snap ring. Remove plunger and spring assembly from cylinder. Remove seal from plunger. DO NOT damage plunger surface.
2. Clean all parts with clean brake fluid. Inspect cylinder bore and plunger for scratches, ridges or scoring. Inspect dust cover for wear or damage. Replace slave cylinder if damaged.

Lubricate NEW seal and cylinder bore with clean brake fluid. Fit NEW seal into groove in plunger. (Scheme 3) Carefully install spring and plunger assembly into cylinder bore. Depress plunger with push rod, and seat snap ring in groove. Lightly grease inside of dust cover and install. Install push rod.

Scheme 3

COMMERCIAL VAN

TORQUE SPECS (COMMERCIAL VAN)

"C/K" SERIES BLAZER & PICKUP, SIERRA, SUBURBAN & YUKON

TORQUE SPECS ("C/K" BLAZER & PICKUP, SIERRA, SUBURBAN & YUKON)

"S/T" SERIES BLAZER & PICKUP, JIMMY & SONOMA

TORQUE SPECS ("S/T" SERIES BLAZER & PICKUP, JIMMY & SONOMA)

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