Archived Clutch Master Cylinder Came Apart

[DGough]

The other morning when starting my 2006 G56 D3500 my foot slipped off the clutch pedal and then the clutch pedal stayed up higher than usual and would not depress. I looked under the dash and discovered that the plastic sleeve at the aft end of the master cylinder had popped out of the master cylinder and was jammed against the firewall. I placed it back into the cylinder and got the truck parked but if I lift up on the clutch pedal it falls back out. Nothing obvious seems to be broken except there was a nylon flanged bushing laying on the floor, however, something is wrong because if the pedal is lifted at all it falls out again. I obviously can't drive it this way. Any thoughts? Has this ever happened to anyone? Do I need a new master cylinder?

 

[GCroyle]

DGough.



Unfortunately you just might need a new M/C at the least.



The push rod has an under cut near the tip that locks into the M/C. The pushrod barb is held in by a retaining clip that is pretty much a one time insertion. I managed to remove one once on a Ford, but it bordered on locksmithing. The retainer has a double retainer system. It locks into the M/C piston with two tabs and then it has two inward pointing tabs that lock onto the barb. As you have experienced, it should be considered a safety function, you don't want your push rod popping out, then you can't release the clutch.



The other pieces are a shoulder washer and foam ring that are used with the saftey start switch.



I'll take a look tomorrow and see if I have an unused retainer anywhere, not sure, sorry. If I have an un-used or possibly useable retainer it's yours if you need it.

 

[GCroyle]

DGough,



Turns out that the retainers are different diameters, just our luck. I have one for a larger OD, but as this is a saftey issue, I recommend that you purchase what is req'd to fix your truck.



Sorry.