Clutch Slipping or Early Clutch Failure (Replace Clutch Assembly and Update Clutch Release System)

Some customers may comment about a slipping clutch or early clutch failure.

For the Eaton Solo (RPO MPK) clutch, the geometry does not have sufficient travel to allow the clutch to self-adjust for wear thus allowing the clutch to become out of adjustment.

For the Valeo (RPO MTD) clutch, the geometry does not allow for sufficient travel for wear. This causes the adjustment service interval required for the clutch to be much more frequent and most owners are not performing this procedure.

The clutch geometry has been updated using components from the C-series trucks and a redesigned clutch actuator and bracket.

Tool Required

J 35990 Clutch Alignment Arbor

1. Remove the transmission from the vehicle.
2. Replace the yoke for the release bearing with the part listed below.
3. Replace the actuator lever with the part listed below.
4. Replace the clutch assembly with the part listed below. Please follow instructions in the installation guide provided with the clutch. These are some key points:

•	Use the studs to support the clutch assembly during installation. DO NOT support on the aligning tool.

•	Ensure proper orientation of the clutch discs and the intermediate plate, as indicated on the components. Align the ceramic buttons on the front and rear disc as closely as possible.

•	Tighten the eight new clutch mounting bolts, P/N 9442012, in a criss-cross pattern and tighten to specifications.

•	FIRST remove the four yellow shipping bolts in a criss-cross pattern, and then remove the aligning tool.

•	LIGHTLY tap on the four intermediate plate separator pins (only a portion of the pin is visible through the access hole).

•	DO NOT force the transmission in or leave the transmission unsupported, as this will damage the discs.

5. Reinstall the transmission.
6. Replace the clutch actuator cylinder and bracket with the parts listed below.

•	Remove the existing L-bracket and move the bracket forward one bolt hole location and invert the bracket.

•	You do not need to bleed the system after actuator replacement because sealed and charged cylinders with quick connects are used.

Important: Do not use a pry bar or similar tool to initially set the clutch as stated in the installation guide provided with the clutch.

7. Cycle the clutch pedal five times in order to set the self-adjusting feature.
8. Measure the clearance between the release bearing and the front cover of the transmission in order to ensure that the clearance is between 12.7 - 14.224 mm (0.500 - 0.560 in).

Important: Due to the increased travel of the new geometry , you may need to adjust the starter-interlock after installing the new system and also may need to adjust the bump stop at the clutch pedal.

Important: Use all of the parts listed for this procedure in order to gain the full benefit of the clutch release system update.

Important: This new set up will still require lubrication of the release bearing.

Parts are currently available from GMSPO.

For vehicles repaired under warranty, use: