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With the truck safely on a jack and supported by jack-stands, we conducted an inspection to pinpoint some of the problems. Other problems and degree of clutch wear would only become evident once the transmission was removed and the old clutch was disassembled.
- Behind the brake master-cylinder is the separate clutch master-cylinder. Both the brake and clutch systems are hydraulic systems and use DOT-3 or DOT-4 brake fluid.
- The clutch master-cylinder connects to the clutch pedal. When the pedal is depressed, fluid and pressure is transferred to the clutch slave-cylinder which functions to disengage the clutch to allow gear-shifting. Our master-cylinder was empty of brake fluid, so it was clearly non-functional.
- Checking from underneath the vehicle, we were able to inspect the slave cylinder and discover that, not only had it broken loose from its mount and was hanging loose, but it was actually coming apart. Clearly the slave-cylinder was in need of replacement, but the fact that it had broken free might be an indicator of further problems with the clutch assembly.
- The next step is to remove the clutch-inspection plate to get a closer look at the clutch assembly. The plate is directly beneath the fly-wheel and is held on by two bolts. Loosen and remove the bolts, and carefully lower the plate out of the way.
- With the plate removed, the edges of the fly-wheel and clutch-disc are visible. From this inspection angle, it can be seen that the clutch is worn thin and in need of replacement.
- The clutch fork is evidently either disconnected from the clutch throw-out bearing or is badly damaged. During operation, the clutch fork presses against the slave cylinder. The damage in this area may explain why the cylinder part dropped off the vehicle.
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