Chevrolet 1977 light duty truck, Service Manual

Page: 773 / 861

11. Install throwout bearing assembly to the
throwout fork. Install clutch and flywheel housing to
engine.
12. Assemble transmission as outlined in Section
7B.
13. Align push rod to clutch fork and attach return
spring to clutch fork.
14. Adjust clutch linkage as described in " M a i n t e ­
nance and Adjustm ents."
CLUTCH DISC AND PRESSURE PLATE
(COIL SPRING TYPE)
Removal From Vehicle
1. Remove transmission as outlined in Section 7B.
2. Disconnect clutch fork push rod and pull back
spring.
3. Remove clutch and flywheel housing.
4. Remove clutch fork by pressing it away from its
ball m ounting with a screwdriver, until the fork snaps
loose from the ball or remove ball stud from rear o f
clutch housing. Remove throwout bearing from clutch
fork.
NOTE: The retain er may be removed from the
fork by prying out with a small screwdriver.
5. Install Tool J-5824 or a used clutch drive gear to
support the clutch assembly during removal.
N O T E : Before rem oving clutch from flywheel,
m ark the flywheel, clutch cover and one pressure
plate lug, so that these parts may be assembled in
their same relative positions, as they were balanced
as an assembly.
6. Loosen the holding screws a turn or two at a
time to avoid b ending rim o f cover. It is advantageous to
place wood or metal spacers (approxim ately 3 /8 thick)
between the clutch levers and the cover to hold the levers
down as the holding screws are rem oved or when clutch
is removed from engine. W h e n rem oving driven plate be
sure to m ark flywheel side.
7. Rem ove clutch pilot tool and remove clutch
assembly from vehicle.
N O T E : Inspect flywheel for heat defects, cracks,
flatness, or other defects.
In stallation To Vehicle
1. Assemble driven plate and clutch cover assem­
bly to flywheel in accordance with m ark in g on driven
plate for flywheel side. Use Tool J-5824 or a d u m m y
sh a ft to support assembly.
2. Line up the clutch assembly with " X " mark or
p a in te d white letter with " X " mark on flywheel, before
tightening cover holding screws.
3. T ig h ten holding screws, a turn at a time, before
rem oving d u m m y shaft.
4. Remove clutch pilot tool.
5. Pack clutch fork ball seat with a small am o u n t
o f high melting point grease and install a new retainer
in the groove o f the clutch fork if the oid retain er is
w orn o r d am aged.
N O T E : Install retainer with high side up, away
from bottom o f the ball socket and with open end
o f retain er on the horizontal.
C A U T IO N :
Be careful not to use too much
lubricant. Excessive lubricant m ay get on
clutch fingers a n d cause slippage.
6. Replace clutch fork ball if rem oved from the
clutch housing and snap clutch fork onto the ball.
7. Pack lubricant in the recess on the insde o f the
throwout b earin g collar and coat the throwout fork
groove with a small am ount o f graphite grease, as shown
in Figure 7C-13.
8. Install throw out b e a r in g assem bly to the
throwout fork. Install clutch and flywheel housing to
engine.
9. Assemble transmission as outlined in Section 7B.
10. Align push rod to clutch fork and attach return
spring to clutch fork.
11. A djust clutch linkage as described in " M a in te ­
nance and Adjustm ents."
C LU TC H PEDAL A R M , PUSH ROD OR
B U S H IN G R E P L A C E M E N T (Fig. 7 C -1 4)
C-K M odels
Removal
1. Disconnect battery negative ground cable at the
battery terminal.
2. Disconnect clutch push rod at the cross shaft
under the vehicle.
3. Remove steering column covers. R em ove screws
retaining push rod boots to bulkhead.
4. Remove air conditioning duct from lower left
side o f instrum ent cluster is so equipped. (R efer to
Section 1A).
CA U T IO N : M aintain pressure on lower arm.
When lower attaching bolt is removed upper
section will snap upward.
5. Disconnect clutch neutral start switch from
pedal arm.
6. Remove bolts attaching lower section o f clutch
pedal arm to the upper arm.
7. Remove lower arm and push rod from vehicle.
8. Remove pedal return spring.
9. Remove pedal pivot shaft retaining nut and
pivot shaft. Insert a d u m m y shaft or rod through the
support to hold the brake pedal com ponents in place.
10. Remove the clutch pedal assembly from the
support assembly.
11. Remove pedal bushings an d spacer from pedal
arm. Check pedal b u m p e r for w ear and replace as
required.