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M/T - Squeaking Noise When Operating Clutch

Bulletin No: 05-001/09

Last Issued: 1/9/2009

Subject:
NOISE FROM CLUTCH RELEASE CYLINDER WHEN CLUTCH IS ENGAGED / DISENGAGED

BULLETIN NOTE
This bulletin supersedes the previous bulletins 05-008/05 issued on 7/1/2005, 05-013/06 issued on 11/30/06, and 05-001/08 issued on 1/22/08 and 5/8/08. The REPAIR PROCEDURE, PARTS INFORMATION, and WARRANTY INFORMATION have been revised.

APPLICABLE MODEL(S)/VINS
2004-2008 B-Series equipped with manual transmission

DESCRIPTION

Some vehicles equipped with a manual transmission may exhibit a squeaking noise when engaging or disengaging the clutch. This may be due to the interface between the clutch release cylinder and the clutch fingers. If so, the clutch release cylinder may have to be replaced. The noise may be duplicated by cycling the clutch with the vehicle standing still and the engine off. The noise has no effect on the durability or function of the clutch system.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern by cycling the clutch with the vehicle standing still and the engine off. Use a stethoscope to confirm the source of the noise is the clutch release cylinder located in the transmission bell housing.

^ If the noise is from the clutch release cylinder, obtain the Dow Corning(R) Molykote(R) G-n Metal Assembly Paste and clutch kit listed in the PARTS INFORMATION and proceed to the NEXT STEP.

NOTE:
^ The use of Dow Corning(R) Molykote(R) G-n Metal Assembly Paste is a critical component of these procedure and must be applied as indicated.

^ If the noise is not from the clutch release cylinder, do not continue with this service bulletin. Follow normal diagnostics as outlined in the Workshop Manual section 05.

2. Remove the transmission. Refer to MS3 online instructions or Workshop manual section 05-11 - MANUAL TRANSMISSION REMOVAL / INSTALLATION.

3. Replace the clutch disc and pressure plate. Refer to MS3 online instructions or Workshop manual section 05-10 - CLUTCH DISC AND COVER REMOVAL / INSTALLATION.





4. Remove the two bolts and the clutch release cylinder from the transmission.

5. Apply a thin film of grease to the new clutch release cylinder bearing face as well as on each of the clutch fingers of the pressure plate.

NOTE:
Apply the grease only where the release bearing contacts the fingers. Only 1-2 oz. (28-57 g) of grease is required per vehicle.





6. Install the new clutch release cylinder. Torque the attaching bolts to 15 lb-ft (20 N.m).

7. Reinstall the transmission. Refer to MS3 online instructions or Workshop manual section 05-11 - MANUAL TRANSMISSION REMOVAL / INSTALLATION.

8. Bleed the clutch release cylinder. Refer to MS3 online instructions or Workshop manual section 05-10 - CLUTCH BLEED PROCEDURE - ON-VEHICLE.

9. Verify repair.

^ Cycle clutch pedal a minimum of 5 times while listening for noise.

^ Verify proper clutch operation.





PART(S) INFORMATION





WARRANTY INFORMATION



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