2004 Chevrolet Silverado 3500
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- Oswin Rich
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1 CLUTCH PEDAL REPLACEMENT Removal Procedure 1. Remove the driver's side knee bolster and deflector. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console. 2. Disconnect and reposition the junction block. 3. Disconnect the clutch pedal position switch electrical connector (1). Fig. 1: Clutch Pedal Position Switch Electrical Connector Saturday, March 05, :48:55 2:49:57 PM Page Mitchell Repair Information Company, LLC.
2 4. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. Fig. 2: Clutch Master Cylinder To Clutch Actuator Cylinder Quick Connect Fitting (NV 3500 or NV 4500 Transmission) Saturday, March 05, :48:55 PM Page Mitchell Repair Information Company, LLC.
3 5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 6. Remove the clutch master cylinder clip from the brake pressure module valve pipe. Fig. 3: Clutch Master Cylinder To Clutch Actuator Cylinder Quick Connect Fitting (ZF S6-650 Transmission) 7. If equipped with a ZF S6-650 transmission, disconnect the clutch master cylinder to clutch actuator Saturday, March 05, :48:55 PM Page Mitchell Repair Information Company, LLC.
4 cylinder quick connect fitting. Fig. 4: Rotating The Clutch Master Cylinder 45 Degrees IMPORTANT: Complete removal of the clutch master cylinder is not required. 8. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. 9. Pull the clutch master cylinder out until the pushrod socket is not touching the clutch pedal. Saturday, March 05, :48:55 PM Page Mitchell Repair Information Company, LLC.
5 Fig. 5: Clutch Pedal Bracket Assembly 10. Remove the clutch pedal to clutch pedal bracket bolt. Saturday, March 05, :48:55 PM Page Mitchell Repair Information Company, LLC.
6 Fig. 6: Clutch Pedal And Brake Module Assembly 11. Remove the clutch pedal to brake module bolts. 12. Remove the clutch pedal sub-assembly. Installation Procedure Saturday, March 05, :48:55 PM Page Mitchell Repair Information Company, LLC.
7 Fig. 7: Clutch Pedal And Brake Module Assembly NOTE: Refer to Fastener Notice in Cautions and Notices. 1. Install the clutch pedal sub-assembly. 2. Install the clutch pedal to brake module bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Saturday, March 05, :48:55 PM Page Mitchell Repair Information Company, LLC.
8 Fig. 8: Clutch Pedal Bracket Assembly 3. Install the clutch pedal to clutch pedal bracket bolt. Tighten: Tighten the bolt to 36 N.m (27 lb ft). Saturday, March 05, :48:55 PM Page Mitchell Repair Information Company, LLC.
9 Fig. 9: Rotating The Clutch Master Cylinder 45 Degrees 4. Push the clutch master cylinder in until the pushrod socket is touching the clutch pedal. 5. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. Saturday, March 05, :48:56 PM Page Mitchell Repair Information Company, LLC.
10 Fig. 10: Clutch Master Cylinder To Clutch Actuator Cylinder Quick Connect Fitting (ZF S6-650 Transmission) 6. If equipped with a ZF S6-650 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. Saturday, March 05, :48:56 PM Page Mitchell Repair Information Company, LLC.
11 Fig. 11: Clutch Master Cylinder To Clutch Actuator Cylinder Quick Connect Fitting (NV 3500 or NV 4500 Transmission) 7. If equipped with a NV 3500 or NV 4500 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 8. Install the clutch master cylinder clip to the brake pressure module valve pipe. Saturday, March 05, :48:56 PM Page Mitchell Repair Information Company, LLC.
12 Fig. 12: Clutch Pedal Position Switch Electrical Connector 9. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 10. Connect the clutch pedal position switch electrical connector (1). 11. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. 12. Position and connect the junction block. 13. Install the driver's side knee bolster and deflector. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console. Saturday, March 05, :48:56 PM Page Mitchell Repair Information Company, LLC.
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