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TSB 06-02-87

Clutch "Chatter", "Roaring" or "Howling" Noise

Visit Geno's Garage for Truck accessories.

Date: August 10, 1987

This bulletin supersedes Technical Service Bulletin 06-03-86, which should be removed from your files.

Models: 1984-1986 D & W Trucks With A-833 or A-435 Manual Transmission & 6-Cylinder Engine Only

Discussion:

Hydraulic clutch system heat shields have been added to the parts packages, and the service procedure has been revised to include instructions for their installation. These shields, the same as were released for Recall #251T, must be installed along with the hydraulic clutch components.  

Symptom/Condition:

Clutch chatter during engagement in first or reverse gear and/or roaring or "howling" noise above 2000 rpm during shifting.  

Diagnosis:

Operate the vehicle for approximately five miles or until the clutch has reached normal operating temperature. Then test for clutch chatter. This is best done by backing the vehicle from a standing start up a short incline. If the concern is for roaring" noise, operate the engine in the 2500-4000 rpm range and perform a normal upshift. The noise can usually be heard when depressing the clutch pedal.

Use the following procedure to correct these conditions. 

Parts Required:

Six Cylinder Vehicles Equipped With A-833 4-Speed Transmission
1    Hydraulic Clutch Actuation Package    PN 4443434  

Six Cylinder Vehicles Equipped With A-435 4-Speed Transmission
1    Hydraulic Clutch Actuation Package    PN 4443435
2    Screw    PN 0181186

NOTES:

1.    REFER TO FIGURE I FOR NOMENCLATURE, TORQUES, AND MOUNTING LOCATIONS OF ALL PARTS.

2.   THE HYDRAULIC CLUTCH SYSTEM IS ALREADY BLED AND PRE-CHARGED WITH FLUID. DO NOT REMOVE THE RESERVOIR CAP OR LOSS OF FLUID WILL RESULT.

3.    DO NOT REMOVE EITHER OF THE WHITE PLASTIC RETAINERS FROM THE CLUTCH ACTUATION CYLINDER OR THE SLAVE CYLINDER PRIOR TO INSTALLATION ON THE VEHICLE.

4.    BE SURE TO INSTALL THE SUPPLIED HEAT SHIELDS OR HEAT DAMAGE TO THE SLAVE CYLINDER COULD RESULT.

Repair Procedure:

1.    Disconnect battery ground cable.

2.    Remove and discard the following clutch parts (with vehicle on floor). a. Clutch pedal push rod b. Clutch pedal assembly

3.    Install the new clutch pedal assembly. Transfer the bushings or replace them if worn. Torque the through bolt to 35 inch pounds.

4.    Locate the "L" shaped template "A" (Figure 2) off the 40-way connector.

NOTE:   SOME MODELS HAVE A GROUND WIRE THAT MAY INTERFERE WITH INSTALLATION OF THE ACTUATION CYLINDER BRACKET. RELOCATE THE GROUND WIRE TO THE RELAY HOLD DOWN BOLT JUST LEFT OF THE GROUND SCREW ATTACHMENT.

5.    Center punch and drill four 11/32" mounting holes. Using a saw, hole drill a 1-3/4" hole in the center position (Figure 3).

 
NOTE: Figures will not reproduce to scale

5.    Center punch and drill four 11/32" mounting holes. Using a saw, hole drill a 1-3/4" hole in the center position (Figure 3).

6.    Locate the rectangular shaped reservoir mounting template above and left, 1" off center, of the 1-1/4" clutch actuation cylinder hole that was just drilled (Figure 4). Make sure the template is pressed down flush with the bulkhead contour and sits snug on the hem flange (Figure 5). Center punch the three hole locations and drill holes with a 1/4" drill.

7.    Install the reservoir bracket, using the three self-tapping screws provided. Torque screws to 95 inch pounds.

8.    Locate and install the reinforcement plate on the inside of the bulkhead. Mark and drill the two 1/4" mounting holes. Install the bracket and torque the screws to 200 inch pounds.

9.   Place a bead of silicone sealer around the actuating cylinder mounting holes and install the bracket. Torque the retaining nuts to 200 inch pounds.

10.  Install the actuating cylinder by inserting it in the mounting bracket and lock in place by twisting it clockwise (Figure 6).

11.   Place the actuating cylinder push rod on the clutch pedal and install the circlip.

NOTE:    DO NOT ATTEMPT TO REMOVE THE WHITE PLASTIC PUSH ROD RETAINER. DO NOT DEPRESS THE CLUTCH PEDAL AT THIS TIME.

12.   Install the reservoir on the reservoir mounting bracket. Torque the screws to 95 inch pounds.

13.   Position the slave cylinder so that it can be installed from under the vehicle. Route and clip the tubing as shown in Figure 1.

14.   Install heat shield on exhaust pipe as shown in Figure 7.

Raise Vehicle

15.   Remove and discard the following parts:

a.    Release fork push rod
b.    Release fork and spring (save the boot for installation)
c.    Clutch pivot shaft assembly and mounting brackets

16.   A-833 Transmissions
Install the slave cylinder mounting bracket and heat shield supplied with the kit (Figure 8). Tighten fasteners to 50 foot pounds.

16.   A-435 Transmissions
Install the slave cylinder mounting bracket and heat shield with the fasteners ordered separately (PN 00181186 - screws). Torque fasteners to 50 foot pounds.

17.   Install the supplied release fork.

18.   Install the original release fork boot.

19.   Install the slave cylinder to the mounting bracket. Torque fasteners to 200 inch pounds.

NOTE:

1.   RECHECK THE HYDRAULIC TUBE ROUTING. MAKE SURE ADEQUATE CLEARANCE EXISTS BETWEEN THE HYDRAULIC TUBE AND THE EXHAUST SYSTEM. ASSURE THAT ALL HEAT SHIELDS SUPPLIED ARE INSTALLED.

2.   DO NOT REMOVE THE WHITE PLASTIC RETAINER FROM THE SLAVE CYLINDER. THE RETAINER WILL BREAK AWAY WHEN THE CLUTCH PEDAL IS DEPRESSED THE FIRST TIME.

20.   Install the supplied plug in the clutch pedal push rod hole in the bulkhead, as this hole is no longer needed.

21.   Lower the vehicle and connect the battery.

The installation is now complete. No adjustment or bleeding is necessary with this package. Simply depress the clutch pedal to break away the plastic retainers and check the clutch for proper operation.

Notes:

POLICY:    Reimbursable within the provisions of the warranty

TIME ALLOWANCE:
Labor Operation No. 06-40-10-95 . . . . . . . . . . 1.3 Hrs.

FAILURE CODE: 2X - Vibration or Chatter