GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 C-Series Medium Duty Truck C6/7/8 - Mexico 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Clutch Lever Replacement

Removal Procedure

    Object Number: 792169 Size: SH
  1. Raise and suitably support the vehicle, if required. Refer to Lifting and Jacking the Vehicle in General Information.
  2. If equipped with the 6.6L or 7.2L engine, with regular production options (RPOs) MUT/MS9/MT3/MK0/ML0, remove the clutch return spring.

    3. Object Number: 792170 Size: SH
  3. If equipped with the 6.6L or 7.2L engine, with RPOs M69/MK8/MK9 and MWW, remove the clutch return spring.

    4. Object Number: 792042 Size: SH
  4. If equipped with the 7.2L engine with RPOs MS9/MT3, remove the clutch pedal adjustment rod swivel retainer (1).
  5. Remove the swivel (5) from the clutch lever.

    6. Object Number: 792043 Size: SH
  6. If equipped with the 6.6L or 7.2L engine with RPOs MUT/MS9/MT3, remove the clutch pedal adjustment rod swivel retainer (1).
  7. Remove the swivel (5) from the clutch lever.

    8. Object Number: 792044 Size: SH
  8. If equipped with the 6.6L engine with RPOs MTD/MK8/MK9 and MWW, remove the clutch pedal adjustment rod swivel retainer (1).
  9. Remove the swivel (5) from the clutch lever.

    10. Object Number: 792046 Size: SH
  10. If equipped with the 6.6L or 7.2L engine with RPOs MK0/ML0/MM7/MNC/MPU, remove the clutch pedal adjustment rod swivel retainer (3).
  11. Remove the swivel (1) from the clutch lever.

    12. Object Number: 793484 Size: SH
  12. Remove the clutch lever nut (4) and washer.
  13. Remove the clutch lever bolt (1) and washer (5).
  14. Remove the clutch lever (2) and key (3).

Installation Procedure


    Object Number: 793484 Size: SH
  1. Install the clutch lever (2) and key (3).
  2. Install the clutch lever washer (5) and bolt (1).

    3. 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.

  3. Install the clutch lever washer and nut (4).

    4. Tighten
    Tighten the clutch lever nut to 16 N·m (12 lb ft).


    Object Number: 792046 Size: SH
  4. If equipped with the 6.6L or 7.2L engine with RPOs MK0/ML0/MM7/MNC/MPU, install the swivel (1) to the clutch lever.
  5. Install the clutch pedal adjustment rod swivel retainer (3).

    6. Object Number: 792044 Size: SH
  6. If equipped with the 6.6L engine with RPOs MTD/MK8/MK9 and MWW, install the swivel (5) to the clutch lever.
  7. Install the clutch pedal adjustment rod swivel retainer (1).

    8. Object Number: 792043 Size: SH
  8. If equipped with the 6.6L or 7.2L engine with RPOs MUT/MS9/MT3, install the swivel (5) to the clutch lever.
  9. Install the clutch pedal adjustment rod swivel retainer (1).

    10. Object Number: 792042 Size: SH
  10. If equipped with the 7.2L engine with RPOs MS9/MT3, install the swivel (5) to the clutch lever.
  11. Install the clutch pedal adjustment rod swivel retainer (1).

    12. Object Number: 792170 Size: SH
  12. If equipped with the 6.6L or 7.2L engine, with RPOs M69/MK8/MK9 and MWW, install the clutch return spring.

    13. Object Number: 792169 Size: SH
  13. If equipped with the 6.6L or 7.2L engine, with RPOs MUT/MS9/MT3/MK0/ML0, install the clutch return spring.
  14. Lower the vehicle, if required.