Service Procedure
1. Disconnect battery.2. Pull carpeting or mat and floor insulation inside of cab, back to expose floor pan in area of clutch pedal.
3. Raise vehicle and remove left front wheel and inner fender panel. (Some units will have cruise control mounted on inner fender panel.) Remove all attachments before pulling inner fender out of wheel opening.
4. Disconnect clutch cables from cordon shaft. Remove cordon shaft retaining nut and washer. Cordon shaft can now be pulled free and laid aside.
NOTICE: Do not remove frame mounted cordon shaft bracket. It will be necessary to use the existing bracket to locate and position the new bracket so as to maintain cordon shaft to engine alignment.
FIGURE 1A - BRACKET:
5. With the cordon shaft removed and the original frame mounted bracket in place, shape the new PIN 14030840 bracket to conform to the toe panel contour (refer to Figure 1A). This can be done with a heavy hammer and vise. For the most part, forming will consist of flatting the 45~ radius just below the two existing bolt holes. The toe pan area will vary from one truck to another making each bracket require individual forming. Close attention in forming bracket to toe pan is necessary to ensure a good mating surface.
NOTICE: Bracket must lay flat against toe pan as shown in Figure 1A to ensure proper load distribution.
6. Using the newly formed bracket as a drilling template and the existing frame mounted bracket to locate cordon shaft in its original location, scribe or mark the two hole locations in toe pan for drilling.
7. Remove the original frame mounted bracket and reinstall the frame bolts to secure brake line clips.
8. Drill the two 3/8 inch marked holes in toe pan and install the two P/N 11504286 bolt and washer assemblies from inside of cab. If standard bolts and flat washers are used, make sure the flat washers are at least 1 inch in diameter to ensure bolt load is evenly distributed at toe pan.
9. (VERY IMPORTANT) THIRD BOLT LOCATION
The third bolt is not listed in parts information due to differences in pinch weld dimension. The third bolt hole and bracket should be drilled with a 1/8 inch pilot hole to ensure bolt will secure bracket to pinch weld. After pilot hole is drilled and alignment is correct, drill and install bolt, washer, nut, and lock washer depending on the dimension of the pinch weld. Check bracket to toe pan mating surfaces to ensure good contact. Flat steel washers can be used to shim between the bracket and pinch weld to prevent stressing the toe pan and bracket.
FIGURE 2 - CORDON SHAFT LOWER ARM:
10. Figure 2 illustrates the addition of weight to the cordon shaft lower are. The addition of weight is used to dampen sound. The installation will differ with 2-wheel and 4-wheel drive units in that the weights will have to be positioned so that they don't interfere with the linkages, exhaust pipe, or in the case of 4-wheel drive, the front driveshaft.
2-Wheel Drive Models (See figure 2)
A. Drill a 5/64 inch retainer (pin) hole through the 2 1/2 inch long 5/16 inch bolt, 1/8 inch from the end.
B. Drill an 11/32 inch hole through the P/N 14063015 large spacer 3/8 inch from the O.D. Note hole location in Figure 2.
FIGURE 3 - CORDON SHAFT LOWER ARM:
4-Wheel Drive Models (See figure 3)
A. Drill a 5/64 inch retainer (pin) hole through the 2 inch long 5/16 inch bolt, 1/8 inch from the end.
B. Drill an 11/32 inch hole through the P/N 14063015 large spacer 3/8 inch from the O.D. Note hole location in Figure 3.
C. Using a hacksaw, cut a notch in the P/N 14063015 large spacer as shown in Figure 3. Since the small spacer is not used on 4-wheel drives, the notch allows clearance for the contour of the lower arm on the cordon shaft.
11. Place cordon shaft back in position and hand tighten washer and nut to toe pan mounted bracket.
12. Reinstall clutch pedal cable with original pin, washer and clip.
FIGURE 4 - LOWER ARM OF CORDON SHAFT:
FIGURE 5 - LOWER ARM OF CORDON SHAFT:
13. Place 5/16 inch bolt through off set hole in larger spacer P/N 14063015. For 2-wheel drives, next place small spacer P/N 14063014 on bolt through existing center hole. Place bolt through hole on lower arm of cordon shaft as shown in Figures 4 or 5. Install lock washer and nut. Torque nut down to collapse lock washer while still being able to rotate large spacer weight.
14. Install clutch release cable, washer, and retainer pin.
15. Replace carpeting and insulation inside of cab.
16. Torque cordon shaft nut to toe pan mounted bracket 20-30 N-m. (15-22 ft.lbs.).
17. Check pedal travel vs. clearance between spacer and exhaust pipe. Rotate the large spacer to clear exhaust pipe and, on 4-wheel drive vehicles, the driveshaft. Torque the jam nut down to lock spacers in correct position. Recommended torque is 20-25 N-m (15-18 ft.lbs.).
18. Adjust clutch cable at transmission clutch release lever. Replace wheel inner fender and attaching parts.
19. Road test for proper clutch operation.
Some trucks may still exhibit clutch chatter after completing the described revision. If this is the case, it will be necessary to remove and inspect the clutch pressure plate and disc assembly.
If the clutch is found to be worn or warped, it should be replaced.
NOTICE: Be sure to inspect the flywheel for warpage and heat checking.
Follow procedures outlined in the Light Duty Service Manual for clutch removal and replacement.