INCOMPLETE CLUTCH RELEASE INSULATION PAD OBSTRUCTS PEDAL

SUBJECT: INCOMPLETE CLUTCH RELEASE - HARD SHIFTING/GEAR CLASH

MODELS: 1990 5H, 6H AND 7H TOPKICK/KODIAK TRUCKS EQUIPPED WITH DIESEL ENGINES AND MANUAL TRANSMISSIONS

Incomplete clutch release, hard shifting and/or gear clashing may be experienced on some of the above subject vehicles. One or more of these con- ditions can occur if the dash panel insulation pad obstructs the clutch pedal from full travel movement.

To correct, it is necessary to cut the dash panel insulation pad by removing the portion that interferes with the clutch pedal. The interference usually occurs in the rectangular hole in the clutch pedal reinforcement bracket located at the top of the clutch assembly. The hole should be free of insula- tion padding.

Use the following corrective measure:

1. While moving the clutch pedal through full travel strokes, inspect the dash panel insulation pad for areas contacting the clutch pedal during travel.

2. Use a utility knife, or other appropriate cutting tool, to remove enough insulation pad in the area that contacts the clutch pedal to provide approximately 25 mm clearance between the insulation pad and the clutch pedal.

3. Remove any insulation from the rectangular hole in the clutch pedal reinforcement bracket located at the top of the clutch assembly.

4. Recheck the clutch pedal travel. If insulation pad interference still exists, trim as necessary.

WARRANTY INFORMATION

For repairs to vehicles under warranty use:

Labor Op: T8150* Labor Time: 0.4 hr.

* 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.