CLUTCH PEDAL SQUEAK NOISE

SUBJECT: CLUTCH PEDAL SQUEAK NOISE (INSTALL GREASEABLE BALL STUD)

MODELS: 1994-95 CHEVROLET AND GMC TRUCK C/K 1,2 AND S/T MODELS WITH NV3500 5-SPEED MANUAL TRANSMISSION (RPOS MG5, MY2, M50)

CONDITION:

A SQUEAK NOISE MAY COME FROM THE CLUTCH AREA WHEN THE CLUTCH PEDAL IS FULLY RELEASED (FOOT OFF THE CLUTCH PEDAL) AND THE ENGINE IS RUNNING. THIS SQUEAK WILL STOP WHEN SLIGHT PRESSURE IS PLACED ON THE CLUTCH PEDAL. THIS NOISE MAY BE CONFUSED WITH A SQUEAKING OR NOISY CLUTCH RELEASE BEARING.

CAUSE:

THIS NOISE IS USUALLY CAUSED BY A DRY CLUTCH FORK BALL STUD WHICH CAUSES METAL TO METAL CONTACT WITH THE CLUTCH FORK. THE GREASE FITTING WAS REMOVED IN PRODUCTION FOR THE 1994 AND 1995 MODEL YEARS SO THE JOINT IS NO LONGER GREASEABLE.

CORRECTION:

INSTALL A GREASEABLE BALL STUD.

SERVICE PROCEDURE

1. REMOVE THE TRANSMISSION FOLLOWING DIRECTIONS IN THE APPROPRIATE SERVICE MANUAL, SECTION 7B, MANUAL TRANSMISSION. 2. REMOVE THE CLUTCH FORK AND BALL STUD FROM THE FRONT TRANSMISSION HOUSING USING J36510, CLUTCH FORK PIVOT REMOVER/ INSTALLER (FIGURE 1). 3. INSPECT THE FRONT TRANSMISSION HOUSING TO LOCATE THE RAISED BOSS WHERE THE GREASE ZERK IS TO BE INSTALLED (FIGURE 2). - THE BOSS IS ON THE RIGHT SIDE OF THE TRANSMISSION BETWEEN THE FILL PLUG AND THE CLUTCH FORK POCKET. 4. DRILL A HOLE OF REQUIRED SIZE (DETERMINED BY DIAMETER/THREAD PITCH OF ZERK USED) IN THE CENTER OF THE RAISED BOSS LOCATED IN STEP 3. - THE GREASE ZERK USED SHOULD HAVE NO MORE THAN 1/4" OF THREADED LENGTH TO AVOID ENTERING THE BALL STUD CAVITY.

IMPORTANT: WALL THICKNESS IN THIS AREA IS APPROXIMATELY 1/4". USE CAUTION TO PREVENT PASSING THROUGH THE BALL STUD CAVITY AND DRILLING THROUGH THE INNER WALL OF THE HOUSING.

5. TAP THE HOLE AS REQUIRED AND INSTALL THE GREASE ZERK.

IMPORTANT: THOROUGHLY CLEAN OUT ALL METAL CHIPS BEFORE INSTALLING THE ZERK AND BALL STUD TO PREVENT PLUGGING THE GREASEABLE BALL STUD.

6. INSTALL GREASEABLE BALL STUD P/N 23049797 USING J36510, CLUTCH FORK PIVOT REMOVER/INSTALLER. 7. GREASE THE FITTING UNTIL A SMALL AMOUNT OF GREASE FLOWS FROM THE END OF THE BALL STUD. 8. INSTALL NEW CLUTCH FORK P/N 15588262. PLACE GREASE IN THE CLUTCH FORK POCKET THAT CONTACTS THE CLUTCH FORK PUSH ROD. 9. REINSTALL THE TRANSMISSION FOLLOWING DIRECTIONS IN THE APPROPRIATE SERVICE MANUAL, SECTION 7B, MANUAL TRANSMISSION. 10. GREASE THE ASSEMBLED BALL STUD LIGHTLY THROUGH THE FITTING. GREASE EVERY 30,000 MILES THEREAFTER.

IMPORTANT: GREASE SHOULD BE ADDED "SPARINGLY" TO THE FITTING. EXCESSIVE GREASE CAN CONTAMINATE THE CLUTCH DISC FRICTION SURFACES RESULTING IN SLIP OR CHATTER AND THE NEED TO REPLACE THE DISC.

SERVICE PARTS INFORMATION

P/N DESCRIPTION QTY 23049797 STUD, CLUTCH FORK BALL 1 15588262 FORK, CLUTCH 1 OBTAIN LOCALLY GREASE ZERK 1

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OP DESCRIPTION LABOR TIME K0720 FORK AND/OR BALL STUD, USE PUBLISHED CLUTCH RELEASE - REPLACE LABOR OPERATION TIME

FIGURES: 3

ATTACHMENTS: 1

CAPTIONS: FIGURE 1 - BALL STUD REMOVAL/INSTALLATION FIGURE 2 - LOCATION OF GREASE FITTING FIGURE 3 - NV3500 IDENTIFICATION INFORMATION

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

COPYRIGHT 1995 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.

THE DOCUMENT SHOWN BELOW SHOULD BE REPRODUCED LOCALLY AND PROVIDED TO THE OWNERS OF THE VEHICLES MODIFIED BY THIS PROCEDURE.

THIS VEHICLE HAS BEEN EQUIPPED WITH A GREASEABLE CLUTCH FORK BALL STUD. LUBRICATE THE CLUTCH FORK BALL STUD THROUGH THE FITTING ON THE CLUTCH HOUSING.

- LUBRICATE THE FITTING AT 30,000 MILE INTERVALS. DO NOT LUBRICATE MORE OFTEN. - LUBRICATE THE FITTING WITH A HAND OPERATED GREASE GUN ONLY. - THE AMOUNT OF GREASE USED SHOULD BE EQUIVALENT TO A BEAD 1/8" IN DIAMETER BY 1/4" LONG. GREASE "SPARINGLY" AS TOO MUCH LUBRICATION MAY CAUSE THE CLUTCH ASSEMBLY TO MALFUNCTION.