HIGH CLUTCH PEDAL POSITION REPLACE STOP BUMPER BRKT.

SUBJECT: HIGH CLUTCH PEDAL POSITION

MODELS: 1990 C5H, C6H AND C7H TOPKICK/KODIAK MEDIUM DUTY TRUCKS EQUIPPED WITH GAS AND DIESEL ENGINES (RPO's LRO, LSO and LXO) AND MANUAL TRANSMISSIONS

Some of the above subject vehicles may experience a high clutch pedal position. This condition can be caused by a bent clutch pedal bump stop bracket.

The clutch pedal bump stop bracket has a 90 degree bend. If the bracket bends beyond the 90 degrees, the clutch pedal height will change.

NOTE Vehicles equipped with early gas engines have a higher designed clutch pedal height (approximately 32mm (1-1/4") to 38mm (1-1/2") than vehicles equipped with diesel engines. Vehicles built after 4-1-90 (Chevrolet VIN 1GBT7H4JOLJ202639 and GMC VIN 1GDJ7H1P4LJ604347) equipped with gas engines have the same approximate clutch pedal height as vehicles equipped with diesel engines. Below is a chart listing the approximate clutch pedal height on vehicles equipped with the following types of engines:

DIESEL EARLY GAS LATE GAS ------------ ------------ ------------ *10.75"-11.0" 12.0"-12.25" 10.75"-11.0"

(*)Height measured from cable anchor cup located in the cab of the vehicle to the top of the clutch pedal.

To correct, it is necessary to replace the bent clutch pedal bump stop bracket using a new stronger bracket. The new bracket is made from thicker and stronger material than the old bracket. The original bracket is 2.Omm thick, the new bracket is 2.7mm thick.

NOTE: Bumper PIN 15671014 is required with the bump stop bracket change. The new bumper MUST be used because the material thickness of the bump stop bracket has changed and as a result the new bracket will not accept the old bumper

REPLACEMENT PROCEDURE (see Figures 1-3):

VEHICLES EQUIPPED WITH EITHER GAS OR DIESEL ENGINES:

A. Remove the bolt, nut and washer from the clutch pedal bump stop bracket and remove the bump stop bracket assembly. The bump stop bracket is located on the clutch pedal assembly. It is not necessary to remove the clutch pedal assembly from the vehicle.

B. Install the new bump stop bracket, P/N 15671005 and bumper P/N 15671014 using existing hardware previously removed. Torque nut to 20-25 N-m (15-18 lbs. ft.).

C. Check clutch pedal free travel and readjust as required to achieve correct range. Refer to the 1990 Medium Truck C5H, C6H, C7H Models Service Manual, Section 7C-6 Clutch, for clutch pedal free travel adjustment instructions.

NOTE: On vehicles equipped with gas engines built prior to 4-1-90 without the new bump stop bracket and bumper, it will be necessary to cut approximately 6mm from the height of the new bumper The new bumper height should match height of removed bumper The original bumper will NOT fit in the new thicker bracket.

SERVICE PARTS INFORMATION:

Part Number Description Quantity -------- ---------------------------------- --------- 15671005 Bump Stop Bracket-Clutch Pedal 1

15671014 Bumper-Bump Stop Bracket Clutch Pedal 1

Parts are currently available from GMSPO.

WARRANTY INFORMATION:

For vehicles repaired under warranty use: Labor Operation: T7086 Labor Time: 0.4 hr.

NOTE: Labor Operation is coded to base vehicle coverage in the warranty system.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.