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Some customers may complain about a “squeak” or “creak” noise when depressing or releasing the clutch pedal. The clutch master cylinder clevis assembly has been improved to eliminate this condition. Repair Procedure 1. Record all radio presets before starting. 2. Disconnect the negative (–) battery terminal cable. 3. Remove the clutch pedal sub–assembly. A. Remove the front door opening trim LH (scuff plate). B. Remove the cowl side trim board. C. Remove the instrument panel finish panel lower No. 1. D. Remove the driver’s side Junction Block. E. Remove the turnover (compression) spring. F. Remove the bolt attached to the instrument panel reinforcement assembly. G. Remove the clutch pedal sub–assembly. a. Remove the bolt and nut. b. Remove the clutch pedal from the clutch pedal support. 4. Remove the clutch pedal spring holder from the clutch pedal support. 5. Remove the clutch pedal pad. 6. Remove the two (2) clutch pedal bushes from the clutch pedal. 7. Remove the clutch pedal shaft collar. 8. Using needle–nose pliers, remove the No. 1 cushion from the clutch pedal. 9. Install the clutch pedal No. 1 cushion on the NEW clutch pedal sub–assembly. NOTE: Install parts on the NEW clutch pedal sub–assembly BEFORE installing in the vehicle. 10. Install the clutch pedal shaft collar. A. Apply MP grease to the clutch pedal shaft collar. B. Install the clutch pedal shaft collar onto the clutch pedal. 11. Install the clutch pedal bushes. A. Apply MP grease to the two (2) NEW bushes. B. Install the two (2) bushes onto the clutch pedal. 12. Install the clutch pedal pad. 13. Install the clutch pedal spring holder. A. Apply MP grease to the contact surface of the clutch pedal spring holder. B. Install the clutch pedal spring holder. 14. Remove the clevis sub–assembly. A. Measure length “A” of the clutch master cylinder. a. Measure length “A” between the lock nut and the thread end with a ruler. b. Record length “A”. B. Remove the clevis sub–assembly from the master cylinder. a. Loosen the lock nut. b. Rotate and remove the clevis sub–assembly. 15. Install the NEW clevis sub–assembly. A. Rotate the lock nut to match length “A”. B. Rotate and install the NEW clevis sub–assembly to contact the lock nut. C. Tighten the lock nut and torque to specification. Torque: 11.8 NSm (120 kgfScm, 8.7 ftSlbf) D. Apply MP grease to the ball end of the clevis sub–assembly where it will contact the clutch pedal. 16. Install the NEW clutch pedal sub–assembly. A. Install the clutch pedal onto the clutch support with the bolt and nut. Torque: 34 NSm (347 kgfScm, 25 ftSlbf) HINT: Install the bolt from the left side of the vehicle. B. Apply MP grease to the clutch pedal sub–assembly where the clevis sub–assembly contacts the clutch pedal. NOTE: Failure to apply grease to the clevis and clutch pedal sub–assemblies could cause the noise to return. C. Tighten the bolt to the instrument panel reinforcement assembly. Torque: 8 NSm (82 kgfScm, 6 ftSlbf) 17. Install the turnover (compression) spring. A. Apply MP grease to the contact surface of the spring holder, clutch pedal, and spring. B. Install the spring onto the clutch pedal and spring holder.

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1. To assemble bearing housing, proceed as follows: a. Using a suitable socket, press bearings into bearing housing. b. Install lock shoe springs, lock shoes and shoe pin into bearing housing. c. Install shoe release lever, spring and pin. d. Install sector drive shaft and snap ring into housing. e. Install lock bolt and engage bolt with sector cam. f. Install rack and spring. Block tooth on rack should engage block tooth on sector. g. Install tilt release lever. h. Install lock bolt spring and retaining bolt. Torque bolt to 35 inch lbs. On C, G and K models, install shift lever spring into housing. On Caballero and El Camino models, install shift lever spring into shift bowl. Install bearing support lock plate and wave washer. On C, G and K models, carefully install shift tube into lower end of steering column jacket. Install wobble plate end of tool J-23073 into upper end of shift tube. Install adapter over end of tube, seating it against the lock plate. Place nut onto threaded portion of tool and pull shift tube into housing. Remove tool. On Caballero and El Camino models, install bearing support thrust washer and retaining ring. Carefully install shift tube into lower portion of steering column jacket. Align shift tube key with shift bowl keyway. Using tool J-23073, pull shift tube into the shift bowl. Install thrust washer and retaining ring. Install actuator rod through support hole between shift bowl and steering column jacket. Install bearing support. Align bearing support “V” with “V” on steering column jacket. Install attaching bolts through support and into lock plate. Torque attaching bolts to 60 inch lbs. Align lower bearing adapter or bushing with notches in steering column jacket. Install lower bearing, bearing reinforcement and retaining clips. Ensure clips align with reinforcement slots on steering column jacket and adapter assembly. Install centering spheres and anti-lash spring onto upper shaft. Install lower steering shaft assembly. On C, G and K models, install steering shaft assembly into shift tube. Install ignition switch actuator rod through shift lever housing. On Caballero and El Camino models, position shift bowl into Park (counterclockwise to stop). Install ignition switch actuator rod between shift bowl and steering column jacket. Assemble bearing housing over steering shaft and engage rack over actuator rod end. On Caballero and El Camino models, position access hole of bearing housing over dimmer switch actuator rod end. While holding the locking shoes in the disengaged position, install bearing housing over steering shaft until pivot pin holes align with holes in support assembly. Install pivot pins. Place bearing housing in the full up (tilt) position. Install tilt lever spring guide, spring and spring retainer. On C, G and K models, proceed as follows: 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

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Accelerator pedal cable -1- connected to accelerator pedal and routed over the Throttle actuator control module cable quadrant. Remove clip -3- from notched section of cable sleeve -4-. Fully depress accelerator pedal to Wide Open Throttle position. Note: Either use a second technician or a mechanical device to depress the accelerator pedal. Vehicles with manual transmission Move notched outer sleeve in or out of grommet -4- (as necessary) until Wide Open Throttle position is just reached. Re-install clip -3- into the first completely exposed notch closest to the top of the grommet. Vehicles with automatic transmission Move outer sleeve in or out of grommet -4- (as necessary) until Wide Open Throttle position is just reached and the kick-down switch clicks audibly. Re-install clip -3- into the first completely exposed notch closest to the top of the grommet. All vehicles Release accelerator pedal (remove mechanical device, if used). After adjusting, check the Closed and Wide open Throttle stops. Vehicles with automatic transmission, adjustment checking Test and auxiliary equipment required Fluke 83 Multimeter VW 1594 Adaptor kit Disconnect 2-pin harness connector from kick-down switch In engine compartment on firewall Connect multimeter between kick-down switch terminals using jumper wires from VW 1594 adaptor kit. Measure resistance across switch. Specified Value: ? Slowly depress accelerator pedal until Wide Open Throttle is reached. If properly adjusted, following conditions will be met: Shortly after kick-down point, resistance must drop to 0 Accelerator pedal must almost be up to the full travel stop

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1. 2. 3. 4. 5. Install the spring retainers to the synchronizer hub. Align the scribe marks previously made on the synchronizer hub and the synchronizer sleeve. Install the synchronizer hub to the synchronizer sleeve with the three struts. Install the main drive synchronizer stop ring to the synchronizer sleeve. Install the drive sprocket to the mainshaft. 6. Install the synchronizer assembly to the mainshaft. 7. Install the synchronizer snap ring to the mainshaft. 8. Use a soft faced hammer in order to install the following components into the annulus gear: • The input gear • The planetary assembly 9. Install the snap ring to the input bearing. 10. Apply RTV GM P/N 12345739 or equivalent to the input shaft bearing retainer mating surfaces. 11. Apply threadlocker GM P/N 12345382 or equivalent to the input shaft bearing retainer bolts. 12. Install the input shaft bearing retainer and the input bearing retainer bolts to the front case half. Tighten Tighten the input bearing retainer bolts to 19 N·m (14 lb ft). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 13. Install the three bolts that secure the encoder motor to the front case. Tighten Tighten the input bearing retainer bolts to 18 N·m (13 lb ft). 14. Install the range shift hub into the front case half. 15. Install the front output shaft to the front case half. 16. Install the driven sprocket to the chain. Important: The following components are installed into the front case half as an assembly: • The mainshaft assembly • The driven sprocket • The drive chain 17. 18. 19. 20. Install the drive chain onto the drive sprocket located on the mainshaft. Install the driven gear snap ring to the front output shaft. Install the mode shift fork onto the shift rail. Install the mode shift fork assembly through the range shift fork, onto the synchronizer sleeve, and into the front case half. 21. Install the mode fork shift spring to the shift rail. 22. Install the following components into the rear case half: • The oil pump pickup tube. • The oil tube connector • The pump pickup screen

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