Clutch Shift Fork - Noise/Squeak

BULLETIN NUMBER
SB95-05-L002

ISSUE DATE
MAY 1995

GROUP
TRANSMISSION

RODEO (UC) CLUTCH SHIFT FORK NOISE/SQUEAK

Affected Vehicles

1991-on Rodeo (UC) 2-wheel drive models equipped with Borg-Warner transmission.

SERVICE INFORMATION

During clutch operation, some affected vehicles may experience a clutch shift fork noise/squeak. This noise or squeak is caused by lack of lubrication on the clutch shift fork pivot ball stud.

By installing a pivot ball stud with a grease passage through its center (see "Parts Information" section), and using the procedures described in this Service Bulletin, the ball stud can be lubricated to eliminate the noise/squeak during clutch operation.

SERVICE PROCEDURE

1. Remove the transmission, slave cylinder, clutch housing, and shift fork, as described in the appropriate Workshop Manual.

2. Remove the ball stud from the clutch housing.




3. Install the new ball stud listed in the "Parts Information" section of this Service Bulletin. Tighten the new ball stud to 35 ft.-lb. (Figure 1).

4. Apply grease to the front end of the new ball stud.

5. If the shift fork shows any signs of wear, install a new shift fork. Reinstall the slave cylinder and transmission, as described in the appropriate Workshop Manual.




6. Locate the ball stud hole in the back of the clutch housing. Using a needle-tipped, hand-operated grease gun, inject grease into the grease passage of the new ball stud, as necessary, to lubricate the shift fork (Figure 2).




7. Seal the ball stud hole in the clutch housing with the rubber plug listed in the "Parts Information" section of this Service Bulletin, to prevent dirt/moisture intrusion (Figure 3).




Parts/Labor Information