Clutches GMC Value Van P2500

DESCRIPTION

The mechanical clutch consists of a driven plate, pressure plate, a diaphragm-type spring, and a release bearing. The driven plate is splined onto transmission clutch shaft so that it can move back and forth when clutch is disengaged and turn the shaft when clutch is engaged.

The driven plate has friction pads riveted to both sides and has a flexible center with springs to absorb vibration. The pressure plate has a machined surface that fits against the driven plate and a diaphragm-type spring mounted in a cover on the pressure plate.

The spring holds the pressure plate and driven plate together against the flywheel when clutch is engaged. The release bearing rides on a sleeve that pushes in on center of diaphragm spring, releasing pressure on the pressure plate and driven plate to disengage clutch.

All vans have a pull rod from clutch pedal that moves a cross lever. All "P" series trucks have an upper pull rod from the clutch pedal to a bellcrank and a lower pull rod from bellcrank to lever to a cross lever. On all models, the cross lever moves clutch fork and the release bearing with an adjustable rod.

Removal (With Muncie 3-Speed Or New Process 4-Speed)

1. Raise and support vehicle. Drain transmission lubricant. Disconnect shift rods and/or shift lever. Disconnect parking brake lever and controls, if used. Mark drive shaft for reassembly reference. Remove drive shaft.
2. Disconnect speedometer cable and wiring from transmission. Disconnect exhaust pipe. Support transmission and remove crossmember. Remove other parts, if needed, for clearance.
3. Remove transmission mount bolts. Move transmission rearward to free from engine. Remove transmission. Note condition and

location of bellhousing plugs; remove if damaged.

Installation

To install, reverse removal procedure. Lightly coat input shaft splines with high temperature grease to aid in reassembly. Install new seal on speedometer cable. Adjust shift linkage. Add lubricant to transmission.

Removal (With General Motors 4-Speed)

1. Remove shift lever boot retainer screws. Slide boot and retainer off lever. Remove shift lever by pushing down and turning collar counterclockwise. Raise and support vehicle.
2. Drain transmission lubricant. Mark drive shaft for reassembly reference. Remove drive shaft. Disconnect speedometer cable and wiring from transmission.
3. Disconnect parking brake lever and controls, if used. Disconnect exhaust pipes. Support transmission and remove crossmember. Remove other parts, if needed, for clearance.
4. Remove transmission mount bolts. Move transmission rearward to free from engine. Remove transmission. Note condition and location of bellhousing plugs; remove if damaged.

To install, reverse removal procedure. Lightly coat input shaft splines with high temperature grease to aid in reassembly. Install new seal on speedometer cable. Adjust shift linkage. Add lubricant to transmission.

Removal

1. With transmission removed, disconnect rod and return spring at clutch fork. Remove bellhousing. Pry against release fork until it pops off ball pivot. Remove release bearing from clutch fork. Mark position of clutch cover on flywheel for reassembly.
2. Install used clutch drive gear to support clutch assembly during removal. Loosen clutch cover bolts 1 or 2 turns at time until clutch plate spring tension is released. Remove used clutch drive gear and remove clutch cover and disc.

Lubricate clutch fork ball seat and recess in release bearing. Reverse removal procedure, making sure clutch hub and pilot bearing are aligned.

1. Disconnect negative battery cable. From inside cab, remove cotter pins, washers, and wave washers. Disconnect pedal rod and bushing. Remove screws and floor pan dust boot. On "P" series, disconnect lower pedal rod.
2. On all models, disconnect pull back spring. Disconnect return spring, if used. Remove cotter pins, washers, and wave washers from fork rod. Note position of fork rod and remove rod.
3. Remove hardware holding cross lever bracket to frame. Remove bracket and cross lever. Remove ball stud, nut, and star washer from bracket. Remove engine side ball stud if worn or damaged.

To install, reverse removal procedure. Lubricate linkage and adjust clutch pedal free play.

1. Disconnect negative battery cable. Remove cotter pin, washer, and wave washer. Disconnect pedal rod and bushing. Note position on clutch/start switch and remove from pedal.
2. Remove nut, spring washer, bolt, and washer. Remove arm and washer. Disconnect clutch pedal return spring. Insert dummy shaft through support and brake pedal to push clutch pedal out and hold components in place. Remove bushings.

To install, reverse removal procedure. Lubricate bushings with petroleum jelly. If necessary, adjust clutch pedal free play.

"G" Series Van Models

1. Hold clutch pedal against bumper. Disconnect return spring at clutch fork. Loosen lock nut and swivel. Move clutch fork back until clutch spring pressure is felt.
2. Turn nut "A" until it is 0.28" (7.1 mm) away from cross lever. (Scheme 1) Tighten nut "B" against cross lever. Install return spring and check pedal free play. Free play should be 1.38" (35 mm).

Van Free Play Adjustment. Scheme 1

"P" Series (Except Forward Control With 4-Wheel Disc Brakes)

1. Hold clutch pedal against bumper. Disconnect return spring at clutch fork. Loosen lock nut and swivel. Remove swivel from cross lever. Move clutch fork back until clutch spring pressure is felt.
2. Adjust rod length until swivel can be easily inserted in gauge hole. (Scheme 2) Increase push rod length until all free play is removed. Remove swivel from gauge hole and insert it in lower hole on lever.
3. Secure swivel with wave washer and cotter pin. Tighten lock nut, making sure that rod length does not change. Install return spring and check pedal free play. Free play should be 1.38" (35 mm).

Free Play Adjustment (Except "P" Series Forward Control W/4-wheel Disc Brakes). Scheme 2

"P" Series (Forward Control With 4-Wheel Disc Brakes)

1. Hold clutch pedal against bumper. Disconnect return spring at clutch fork. Loosen lock nut and swivel. Move clutch fork back until clutch spring pressure is felt.
2. Turn nut "A" until it is 0.29" (7.4 mm) away from rod shoulder. (Scheme 3) Tighten nut "B" against clutch fork. Tighten swivel lock nut until all free play is removed. Install return spring and check pedal free play. Free play should be 1.50" (38 mm).

Free Play Adjustment ("P" Series Forward Control W/4-wheel Disc Brakes). Scheme 3

CLUTCH RELEASE

Start engine and apply brakes. Depress clutch pedal until it is about 1/2" (13 mm) from floor mat. Shift back and forth between 1st and Reverse. If shifts are smooth, clutch is working properly. If shifts are not smooth, clutch is not releasing fully. Adjust clutch pedal free play.

LINKAGE

Check linkage for bending or damage. Check for worn swivels, loose, and damaged mount brackets. Inspect clutch lever for bending, wear, or damage. Ensure there is clearance between clutch and mount brackets, and between ball studs. If linkage is okay, lubricate clutch linkage.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS