Clutches GMC Sonoma Syclone

DESCRIPTION

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

TRANSMISSION APPLICATION

ADJUSTMENTS

The hydraulic clutch system is nonadjustable.

HYDRAULIC SYSTEM BLEEDING

Note. Never reuse fluid which has been bled from the system.

1. Fill reservoir with clean DOT 3 brake fluid. Disconnect slave cylinder from bellhousing, leaving line attached. Hold slave cylinder at a 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.

CHECKING HYDRAULIC CLUTCH SYSTEM

Check hoses for cracks, wear or other damage. Check hydraulic cylinders for loose mounting and signs of leakage. Clutch pedal travel should be at least 6" (152.5 mm). Secondary push rod travel at clutch fork should be at least .75" (19 mm). If necessary, bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING .

Removal (BW-1370 & 4470 "K" Series With Dual Rear Wheels)

1. Disconnect negative battery cable. Place transfer case in 4H position. Raise vehicle. Remove skid plate. Drain lubricant from transfer case. Mark front drive shaft and flange for reassembly reference. Remove front drive shaft.
2. Remove left strut rod. Mark rear drive shaft and flange for reassembly reference. Remove rear drive shaft. Disconnect electrical connectors from transfer case. Disconnect shift linkage at transfer case.
3. Support transfer case. Remove transfer case-to-transmission bolts. Remove transfer case by moving transfer case rearward until it is free of transmission output shaft. Remove old gasket material.

Installation (BW-1370 & 4470 "K" Series With Dual Rear Wheels)

To install, reverse removal procedure. Install a new gasket and fill transfer case with Dexron-II.

Removal (NP-205 & NP-241 "C", "K" & "V" Series)

1. Disconnect negative battery cable. Raise and support vehicle on hoist. Remove skid plate. Drain transfer case. Mark rear drive shaft components for reassembly reference. Disconnect and remove rear drive shaft from vehicle.
2. Mark front drive shaft components for reassembly reference. Disconnect and remove front drive shaft from vehicle. Disconnect vent hose and electrical connectors from transfer case. Disconnect speedometer cable and shift linkage at transfer case. Remove transfer case strut rod (if equipped).
3. Support transfer case. Remove transfer case-to-transmission bolts. Move transfer case to rear until clear of transmission. Lower transfer case assembly from vehicle.

Installation (NP-205 & NP-241 "C", "K" & "V" Series)

To install, reverse removal procedure. Install a new gasket and fill transfer case with Dexron-II.

Removal (NP-231 "S" & "T" Series)

1. Disconnect negative battery cable. Move transfer case shift lever to 4H position. Raise vehicle and remove skid plate. Drain transfer case. Mark front and rear output shaft yokes and drive shafts for reassembly reference. Remove shafts.
2. Disconnect speedometer cable and vacuum harness from transfer case. Disconnect shift linkage from case. Remove catalytic converter hanger bolts at converter, and loosen front catalytic converter clamp.
3. Raise transmission and transfer case assembly with jack, and remove transmission mount bolts. Remove catalytic converter front bracket. Lower complete assembly. Support transfer case alone, and remove transmission-to-transfer case bolts. Remove transfer case from vehicle.

Installation (NP-231 "S" & "T" Series)

To install, reverse removal procedure. Install a new gasket and fill transfer case with Dexron-II.

Removal ("C", "K", "R" & "V" Series)

1. Disconnect negative battery cable. On 2WD models, remove shift lever boot attaching screws. Slide boot up the shift lever. Shift transmission into Neutral and remove lever.
2. On 4WD models, remove center console, shift boot, boot bridge and selector switch. On all models, raise and support vehicle. Remove skid plate and disconnect vacuum harness.
3. On all models, remove drive shaft(s). Carefully remove transfer case (if equipped). Disconnect speedometer cable and wiring from transmission. Remove clutch slave cylinder. Support transmission and remove transmission mounting bolts.
4. Remove exhaust pipes, crossmember and any other components as necessary for clearance. Remove dust cover bolts. Remove transmission mounting bolts. Remove transmission.

Installation ("C", "K", "R" & "V" Series)

To install, shift transmission into high gear and reverse removal procedure. Lightly coat input shaft splines with high-temperature grease. See TORQUE SPECIFICATIONS ("C" & "K" SERIES) or TORQUE SPECIFICATIONS ("R" & "V" SERIES) table.

Removal ("S" & "T" Series)

1. Disconnect negative battery cable. Remove shift lever boot. Shift transmission into Neutral. Disconnect shift control rods (if equipped). Remove shift lever.
2. Raise and support vehicle. Remove brake cable for clearance. Mark drive shaft for reassembly reference. Remove drive shaft.
3. Disconnect speedometer cable and wiring from transmission. Disconnect exhaust pipe. Support transmission. Remove support braces and skid plate (if equipped). Remove other components as needed for clearance.
4. Remove clutch slave cylinder from transmission. Remove crossmember. Remove transmission-to-engine bolts. Remove transmission from vehicle.

Installation ("S" & "T" Series)

1. To install, reverse removal procedure. Lightly coat input shaft splines with high-temperature grease to aid in reassembly. Refer to the «TORQUE SPECIFICATIONS ("S" & "T" SERIES)»(/gmc/sonoma-syclone/1991-1992/remont/clutches-manual-hydraulic/#clutches) .
2. Shift transmission into high gear. Install support braces. Tighten braces to clutch housing before tightening to transmission. Install new seal on speedometer cable. Adjust shift linkage. Add transmission lubricant Dexron-II.

CLUTCH ASSEMBLY & PILOT BEARING

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

Removal

1. Remove transmission. See «TRANSMISSION»(/gmc/sonoma-syclone/1991-1992/remont/clutches-manual-hydraulic/#clutches) under REMOVAL & INSTALLATION. Remove slave cylinder from bellhousing. (Scheme 1) Remove screws and flywheel cover. Remove bellhousing. Remove clutch fork and release bearing. Remove ball stud or clutch fork retainer if worn or damaged.
2. Install clutch pilot in clutch disc during removal. Mark flywheel and pressure plate for reassembly reference. Evenly loosen pressure plate bolts 1-2 turns at a time until clutch plate spring tension is released. Remove clutch pilot, pressure plate and clutch disc.

Installation

1. Support clutch disc and pressure plate on flywheel with clutch pilot. Ensure reference marks are aligned. Tighten bolts evenly to avoid distortion.
2. Remove pilot. Lubricate ball stud and 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. (Scheme 1) Reverse removal procedure to complete installation.

Scheme 1

1. Disconnect negative battery cable. Remove steering column covers or panel. On "C", "K" and "S" Series, remove A/C duct from lower left side of instrument panel.
2. On all models, disconnect push rod from clutch pedal. Disconnect reservoir hose at master cylinder. Remove master cylinder retaining nuts. Remove master cylinder.

To install, reverse removal procedure. Bleed system. See HYDRAULIC SYSTEM BLEEDING .

Scheme 2

Removal & Installation

Disconnect negative battery cable. Raise and support vehicle. Disconnect and cap hydraulic line at slave cylinder. Remove slave cylinder. To install, reverse removal procedure. Bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING .

Scheme 3

Disassembly & Inspection

1. Pull out reservoir adapter and adapter seal. Pull back dust cover and remove snap ring from cylinder. Extract push rod. Remove plunger and spring assembly. (Scheme 2)
2. Remove spring from front of plunger. Remove seal support, front seal and shim from plunger. Be careful not to damage plunger surface. Clean all parts with clean brake fluid.
3. Ensure cylinder bore is smooth. Inspect bore for visible ridges or scores. Replace master cylinder if scored or damaged.

Reassembly

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

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 in clean brake fluid. Inspect cylinder bore for ridges or scratches. Bore must be smooth. Replace cylinder if damaged.

Place seal in groove on plunger. (Scheme 3) Lubricate bore and seal with clean brake fluid. Slide spring and plunger assembly into cylinder bore. Depress plunger far enough to install snap ring in groove. Lightly grease inside of dust cover and install boot. Install push rod.

"C" & "K" SERIES

TORQUE SPECIFICATIONS ("C" & "K" SERIES)

"R" & "V" SERIES

TORQUE SPECIFICATIONS ("R" & "V" SERIES)

"S" & "T" SERIES

TORQUE SPECIFICATIONS ("S" & "T" SERIES)

See also:
• HYDRAULIC SYSTEM BLEEDING
• TORQUE SPECIFICATIONS ("C" & "K" SERIES)