Tuesday, May 3, 2011

How to remove clutch parts on 2001 GMC Sierra?

Master Cylinder


Removal & Installation



  1. Disconnect the clutch pedal position switch electrical connector.
  2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal.
  3. If equipped with a NV 3500 or NV 4500 transmission:
    1. Disconnect the clutch slave cylinder to clutch master cylinder quick connect fitting.
    2. Remove the clutch master cylinder clip from the brake pressure module valve pipe.

  4. If equipped with a ZF S6-650 transmission:
    1. Disconnect the clutch slave cylinder to clutch master cylinder quick connect fitting.
    2. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position.

  5. Remove the clutch master cylinder.

    Click image to see an enlarged view

    Fig. Clutch slave cylinder to clutch master cylinder quick connect fitting- NV 3500 or NV 4500 transmissions



    Click image to see an enlarged view

    Fig. Clutch slave cylinder to clutch master cylinder quick connect fitting-ZF S6-650 transmission


To install:

  1. If equipped with a ZF S6-650 transmission
    1. Install the clutch master cylinder.
    2. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position.
    3. Connect the clutch slave cylinder to clutch master cylinder quick connect fitting.

  2. If equipped with a NV 3500 or NV 4500 transmission
    1. Install the clutch master cylinder.
    2. Connect the clutch slave cylinder to clutch master cylinder quick connect fitting.

  3. Install the clutch master cylinder clip to the brake pressure module valve pipe.
  4. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal.
  5. Connect the clutch pedal position switch electrical connector.
  6. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete.

  1. Disconnect the clutch pedal position switch electrical connector.
  2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal.
  3. If equipped with a NV 3500 or NV 4500 transmission:
    1. Disconnect the clutch slave cylinder to clutch master cylinder quick connect fitting.
    2. Remove the clutch master cylinder clip from the brake pressure module valve pipe.

  4. If equipped with a ZF S6-650 transmission:
    1. Disconnect the clutch slave cylinder to clutch master cylinder quick connect fitting.
    2. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position.

  5. Remove the clutch master cylinder.

    Click image to see an enlarged view

    Fig. Clutch slave cylinder to clutch master cylinder quick connect fitting-NV 3500 or NV 4500 transmissions



    Click image to see an enlarged view

    Fig. Clutch slave cylinder to clutch master cylinder quick connect fitting-ZF S6-650 transmission


To install:

  1. If equipped with a ZF S6-650 transmission
    1. Install the clutch master cylinder.
    2. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position.
    3. Connect the clutch slave cylinder to clutch master cylinder quick connect fitting.

  2. If equipped with a NV 3500 or NV 4500 transmission
    1. Install the clutch master cylinder.
    2. Connect the clutch slave cylinder to clutch master cylinder quick connect fitting.

  3. Install the clutch master cylinder clip to the brake pressure module valve pipe.
  4. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal.
  5. Connect the clutch pedal position switch electrical connector.
  6. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete.
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Driven Disc & Pressure Plate


Removal & Installation



  1. Remove or disconnect the following:

    Transmission
    Quick disconnect from the slave cylinder

  2. Install a clutch alignment tool.
  3. Mark the flywheel and a clutch pressure plate lug for the installation alignment.
  4. Remove the pressure plate bolts and the washers.
  5. Secure the clutch pressure plate and the clutch driven plate to the flywheel.
  6. Remove the clutch alignment tool.

To install:

  1. Install the bolts and the washers securing the clutch pressure plate and the clutch driven plate to the flywheel.
  2. Install the clutch alignment tool.
  3. Align the marks made during removal or, if new align the lightest part of the clutch pressure plate identified by a yellow dot, to the heaviest part of the flywheel, identified by an "X". Tighten the clutch pressure plate to the flywheel bolts to 52 ft. lbs. (70 Nm) in a crisscross pattern.
  4. Remove the clutch alignment tool.
  5. Install the transmission.
  6. Install the quick disconnect to the concentric slave cylinder.

  1. Remove or disconnect the following:

    Transmission
    Quick disconnect from the actuator cylinder

  2. Install a clutch alignment tool.
  3. Mark the flywheel and a clutch pressure plate lug for the installation alignment.
  4. Remove or disconnect the following:

    Pressure plate bolts and the washers

  5. Secure the clutch pressure plate and the clutch driven plate to the flywheel.
  6. Remove the clutch alignment tool.

To install:

  1. Install the bolts and the washers securing the clutch pressure plate and the clutch driven plate to the flywheel.
  2. Install the clutch alignment tool.
  3. Align the marks made during removal or, if new align the lightest part of the clutch pressure plate identified by a yellow dot, to the heaviest part of the flywheel, identified by an "X". Tighten the clutch pressure plate to the flywheel bolts to 41 Nm (30 ft. lbs.).
  4. Remove the clutch alignment tool.
  5. Install the transmission.
  6. Install the quick disconnect to the concentric slave cylinder.

  1. Remove or disconnect the following:

    Transmission
    Quick disconnect from the slave cylinder

  2. Install a clutch alignment tool.
  3. Mark the flywheel and a clutch pressure plate lug for the installation alignment.
  4. Remove the pressure plate bolts and the washers.
  5. Secure the clutch pressure plate and the clutch driven plate to the flywheel.
  6. Remove the clutch alignment tool.

To install:

  1. Install the bolts and the washers securing the clutch pressure plate and the clutch driven plate to the flywheel.
  2. Install the clutch alignment tool.
  3. Align the marks made during removal or, if new align the lightest part of the clutch pressure plate identified by a yellow dot, to the heaviest part of the flywheel, identified by an "X". Tighten the clutch pressure plate to the flywheel bolts to 52 ft. lbs. (70 Nm) in a crisscross pattern.
  4. Remove the clutch alignment tool.
  5. Install the transmission.
  6. Install the quick disconnect to the concentric slave cylinder.
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Slave (Actuator) Cylinder

Removal & Installation



  1. Remove the manual transmission.
  2. Remove the clutch slave cylinder bolts.
  3. Remove the clutch slave cylinder. If required, the clutch release bearing can be removed from the clutch slave cylinder for replacement.

To install:

  1. Install the clutch slave cylinder.
  2. Install the clutch slave cylinder bolts.
    1. Tighten the bolts to 71 inch lbs. (8 Nm).

  3. Install the manual transmission.

  1. Remove the manual transmission.
  2. Remove the clutch slave cylinder bolts.
  3. Remove the clutch slave cylinder. If required, the clutch release bearing can be removed from the clutch slave cylinder for replacement.

To install:

  1. Install the clutch slave cylinder.
  2. Install the clutch slave cylinder bolts.
    1. Tighten the bolts to 71 inch lbs. (8 Nm).

  3. Install the manual transmission.

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