Clutch is still not right

[jackcaptjr]

Well the saga continues. Have had clutch actuator problems almost from day one. A rough pedal and a poping that you can feel when pushing the clutch in. Dealer has been very pleasent and has changed the hyd unit twice and this time the bushings and under dash assembly. All repairs seem to have a positive effect for a short period of time. The roughness in the pedal is engine speed sensetive about 2K and higher but the poping is intermitent and not engine speed related. Frustration is setting in... ... Gen 2 truck had rough pedal issue after driving through very heavy rain conditions but seemed to go away after a period of time..... never had the poping. Any ideas???????? The poping will get worse with time... ..... right now only occurs 10% of the time. In 2500 miles it will be 50% of the time.

Guess I will have to fix it myself... ... ... thought that was what the warrenty was for?????

 

[DLeno]

by "popping" do you mean it feels like the pedal catches on something? and you dont feel anything like this when releasing -- only when depresssing the clutch?



reason I ask is that I've been fighting a "catch" in my clutch travel when releasing it slowly. the dealer replaced the hydr unit and now the problem is coming back. in my case the problem appears to go away when everything is cold.



was it you that reported (earlier, in a different thread) that the bushing replacement fixed the problem

 

[jackcaptjr]

I don't think I reported that bushings fixed the problem... ... ..... just had that done a couple of weeks ago and don't think I posted it??????



The "poping" occurs on depressing the clutch only and you feel it. Hard to describe but you can feel it and sometimes hear it... ... . almost like some sort of hang up or catching??????? Seems to be inside the cab????????

 

[DLeno]

oh. sorry for the red herring. you and I have different problems.

 

[SRadke]

There is a plastic pin that attaches the master cylinder to the pedal. I'd pop that pin out and pull the master cylinder out of the way (through the firewall, just twist CCW it pops out) so you can run the stroke of the pedal without it attached to the master cylinder. A popping in a hydraulic system has to be either in the linkage or a hangup in one of the two cylinders. A new Hydraulic assembly should have already ruled that out.



-Scott

 

[jackcaptjr]

Thanks Scott... ... ... I have about given up on the dealer... ... ... . Nice guys BUT?????



I will look into your suggestion this weekend. Feels like something in the linkage poping or slipping into place. Must be pretty subtle or shotgunning all the parts should have fixed it????? Just doesn't feel like it is on the other side of the hyd..... clutch itself works fine, nice and smuuuuuth?????

 

[SRadke]

These are a really simple system. Granted they are mostly plasic parts which bothers me a little but if you've already replaced the whole hydraulic assembly the pedal is about all that's left.



If you don't have the adjustable pedal option all you've got is a pedal on a hinge with the master cylinder pined in the middle. The master cylinder is very easy to pull through the firewall from the outside just twist the whole unit CCW less than 1/4 turn and it will pull out. I recently replaced my whole hydraulic assembly with the older style because it will take the higher pedal pressure of a dual disk clutch.



-Scott



On edit... . perhaps your hangup is in the sliding clutch switch? It's easy to remove, pinch two white ears and slide the plastic keeper back. The keeper falls off and the switch pops off the rod on the opposite side. You may try removing it and see if you still have a pop. Keep in mid the truck won't start without it though.

 

[jelag]

I posted a reply to this yesterday and it didn't get there because of a glitch in my computer... . some thoughts on what you might wish to consider... .



The release bearing slides on the input shaft... if there is any kind of dirt, or it was never lubed at installation you might have the release bearing hanging up on the input shaft...



The pilot bearing is an accident waiting to happen... if one of the needles in the pilot bearing is bad, worn or missing it will allow the disc to clamp up off the center line of the crank... causing vibrations, hard shifting, poor release problems and finally clutch disc failure and damage to the input shaft bearings from miss-alignment...



The end of the slave has a plastic button on the rod. . this takes up some space... serves as a friction reducer as the rod pushes on the fork, make sure it's there and is not broken..... I've seen this button missing and you can't get enough stroke to get the cover to release... .



If you consider how many million hyd clutch systems are out there I'm guessing your problem is somewhere else...



Hope this have given you some other areas to consider...

 

[Trent]

http://www.dieseltruckresource.com/dev/showthread.php?t=82005

 

[Nightram]

Check the thread out there for new noise, clutch is clicking. It sounds like you have the same thing we all do, try some silicone spray on the clutch pedal rod, may be the clutch pedal position switch hanging up. Just make sure to keep the slicone away from the rubber by the master cylinder boot