Clutch problems?

Tiny
RISKYBIDNES
  • MEMBER
  • 2002 CHEVROLET SILVERADO
  • 4.8L
  • V8
  • 4WD
  • MANUAL
  • 180,000 MILES
I ran this truck for 16 years with no problems with the clutch. Slave cylinder had a bad leak, so I figured it was time to get the clutch redone. The mechanic installed a new slave cylinder and all the new components throughout. Clutch didn't act right after I got it back, seemed to release closer to the floor than I remembered. Anyway, about a year goes by and the new slave starts leaking again. The mechanic installed an entire new clutch again, because it was still under warranty. This time the clutch released really close to the floor. But I figured it was an old truck and I'd just have to live with it like that. It's been about a year and half now, and it started getting really hard to get into first gear and reverse. I checked master cylinder and hadn't lost any fluid. I pumped the clutch up at the pedal a bunch and it was easier to get into gear. I thought okay fixed. Wrong. It bled down overnight and lost no fluid but lost pressure if that makes sense. I thought maybe there was air in the line, so I bled the line repeatedly. Clutch worked well, next day went to drive to work and couldn't get into gear, bled pressure down again. Pumped it repeatedly, got it built up and went to work. The same thing happened at lunch and after work. I really don't want to have to pay to have another clutch installed, considering the clutch, pressure plate and everything else besides slave cylinder were still in pristine condition the first time after almost 145,000 miles. So, I'm sure the internal parts of the clutch are good. I took a picture of the slave cylinder through the hole in the side, and it looked dry and clean. After trying to suck out air from the line, the pedal is just flopping at this point. Would I be wrong to assume this is a master cylinder problem? Can the master cylinder go bad, let air in the system and not lose fluid in the process? I am hoping so, I ordered a master Tuesday and am waiting for it to arrive. Also, I've read there is possibly a bleeder valve in the hole above the one I took this picture from. I can't get my hand to the hole without a lot of extra effort. Is there a bleeder valve inside that hole? How do you access it? Thanks again for any help! Thanks for any help or guidance on this.
Saturday, August 19th, 2023 AT 4:41 PM

4 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 48,363 POSTS
Thanks for the image. It does sound like the clutch master needs to be replaced. Here is a guide that can help, and I have included how to change the clutch master out in the images below:

https://www.2carpros.com/articles/clutch-doesnt-work-sometimes-or-not-at-all

Check out the images (below). Let us know what happens and please upload pictures or videos of the problem so we can see what's going on.

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Sunday, August 20th, 2023 AT 12:34 PM
Tiny
RISKYBIDNES
  • MEMBER
  • 3 POSTS
Thanks for the pictures. Installed the master cylinder this evening. No problems. Bleeding the system still not right. I had to pump pedal about 500 times to get pressure enough to change gears. It didn't last long, depleted pressure about 3 miles into test drive. I have no apparent leaks, fluid level stays same, just losing pressure.
I got no clue what to do now. Just keep pumping that freaking pedal at stop lights and every time I start the truck I guess.
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Monday, August 21st, 2023 AT 7:16 PM
Tiny
RISKYBIDNES
  • MEMBER
  • 3 POSTS
I used a piece of tubing and a small tip from my mitymax pressure pump. I pulled vacuum with my mouth, bubbles galore. I kept doing that until I saw no more bubbles, about 15 rounds. Then pumped pedal again, a bunch of times to get pressure built up. It literally lasted 10 shifts and back to being difficult again. Releasing at the floor, hard to get into 1st and reverse. Noticed that with the cap off, had my son pushing pedal and every once in a while a pump of the clutch would cause a major blurp to shoot out the master cylinder. It didn't look like air bubble, just fluid pushing up. Maybe was air, not sure.
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Monday, August 21st, 2023 AT 7:21 PM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 48,363 POSTS
Sorry about that, it sounds like you may have a defective secondary cylinder, while the transmission is out, check the clutch disc and pressure plate. I would get a high-quality clutch kit and resurface the flywheel. This video shows the job being done on a similar vehicle; the process is the same:

https://youtu.be/JpzefqEeVGE?si=zfug4wt12WyeD-_D

Here is how the job is done on your truck. Check out the images (below). Please let us know what happens.

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Tuesday, August 22nd, 2023 AT 11:25 AM

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