GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2005 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Clutch Pedal Free Travel Adjustment

Clutch Pedal Free Travel Adjustment Pedal Free Travel

  1. Apply the park brake.

    2. Object Number: 793808 Size: SH
  2. Loosen and adjust the jam nuts (2) and (3) to obtain proper pedal free travel.

    3. Object Number: 793764 Size: SH
  3. Free travel distance of clutch pedal (7-2) should be 1.5-2 in.

    4. Specification
    38-51 mm (1.5-2.0 in)

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 793808 Size: SH
  4. Tighten the jam nut (3) and jam nut (2).

    5. Tighten
    Tighten the jam nuts to 40 N·m (30 lb ft).

  5. Disengage the park brake.
  6. Check the clutch system for normal operation.

Clutch Pedal Free Travel Adjustment MPK Resetting Procedure in Vehicle

Reset the clutch if one or more of the following conditions occurs:

    • The clutch was removed for engine repair.
    • The clutch was unbolted from the flywheel without first installing the shipping/resetting bolts.
    • The clutch unbolted from the flywheel in order to realign the discs during clutch installation.
    • The clutch pedal was depressed after clutch installation and one of the following conditions occurs:
    • More than 25.4 mm (1 in) of free pedal is present in the clutch pedal.
    • The release bearing moved near the transmission.
    • The clutch tab moved halfway towards the WORN/REPLACE position.

Clutch Recalibration Procedure
  1. Hold the clutch pedal in the disengaged position.

    2. Object Number: 732418 Size: SH

    Important: The wear indicating tab should move with finger pressure. Do not force the tab to the NEW position.

  2. Move the clutch wear tab to the NEW position. If the clutch wear tab does not move to the NEW position with finger pressure.
  3. Release the clutch pedal.
  4. The solo wear indicating tab is now reset.

    5. Object Number: 732382 Size: SH

    Important: It will be necessary to rotate the flywheel in order to gain access to all 4 clutch pressure plate shipping bolts.

  5. Install 4 3/8 inch x 16 x 1-1/4 inch UNC hex head bolts -- the same bolts used to cage the pressure plate when the clutch was shipped. Use the inspection window in the transmission bell housing in order to gain access to the pressure plate. Turn the 4 bolts, until the pressure plate is fully retracted.

    6. Specification
    0.062 gap under each tamper proof plate spacer bolt with the pedal pushed to the floor


    Object Number: 732425 Size: SH
  6. Remove all 4 bolts. Ensure that there is no gap between the plate spacer roll pin and the tamper proof plate spacer bolt when the clutch pedal is in the up position.

    7. Object Number: 732382 Size: SH
  7. Depress the clutch pedal (compressing clutch brake) 5 or more times in order for the Solo to automatically reposition the bearing.