Inspection Procedure

1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5" (12.7 mm) from the floor.

2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear.

3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article.

4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the Suggested Bleeding Procedure at the end of this article.

5. Test drive the truck and check for improved clutch release.
6. If there is no improvement, proceed as follows:

a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever.

Figure 1:

b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force for installation, Figure 1.

c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines.

7. Test drive the truck again, checking for improved clutch release.

Figure 2:

8. If there is no improvement, inspect the truck for adequate release bearing travel.

^ It should be 11 mm or greater for full pedal travel.

^ Pedal travel at the center of the pedal pad should be 6.75" (171 mm minimum) or more, Figure 2.

9. Release bearing travel and gear grinding noise may indicate the following concerns.
^ If the release bearing is 11 mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission.

^ If all gears grind, the concern may be with the clutch and/or pilot bearing which will need replacing.
^ If the release travel is less than 11 mm, check the clutch hydraulic system for air and bleed as necessary.

10. If the release travel is still less than 11 mm, with all of the above items eliminated, proceed as follows:
a. Raise the hood, while an assistant operates the clutch pedal.

b. Watch the clutch master cylinder for significant deflection.

Figure 3:

c. Look for the dash reinforcement moving away from the dash, Figure 3.

d. On 1987 and earlier models, look down inside the cowl cover at the cowl where it is attached to the dash reinforcement. Check for pulled spot welds.

11. If there is significant movement of the dash or clutch master cylinder, proceed as follows:

a. Remove the steering column and its dash toe plate and seal. Refer to the appropriate Light Truck Shop Manual, Section 13-07 for service details.

b. Inspect the dash inside the cab and look for:

^ Pulled spotwelds and cracked or torn sheet metal.

^ Cracks in the brake and clutch pedal support

Figure 4:

^ Missing Y-brace fasteners and a broken or detached Y-brace, Figure 4.

12. Check the cross shaft bushings for wear if the brake pedal moves when the clutch is depressed and vise versa. Replace them as required.

NOTE: GENERALLY, TRUCKS WITH SIGNIFICANTLY LESS THAN 11 MM CLUTCH RELEASE BEARING TRAVEL (AFTER COMPLETING THE INSPECTION PROCEDURE AND CORRECTING WHERE NECESSARY) WILL HAVE SIGNIFICANT DASH DAMAGE FROM PULLED SPOTWELDS AND TORN METAL. THESE TRUCKS WILL REQUIRE EXTENSIVE REPAIR. THEREFORE, GO TO THE LARGE REINFORCEMENT INSTALLATION PROCEDURE.