270799 Posts in 19739 Topics - by 1830 Members - Latest Member: Simplesimon

Hello Guest
Show unread posts since last visit.
Show new replies to your posts.

Author Topic: DIY - 2nd Gen Clutch Install  (Read 24881 times)

Offline Kilch123

  • Regular Member
  • Mechanical God!!!
  • *
  • Posts: 10466
  • Thanks Pat and Adam!!!
  • Awards:
    DECEMBER ROTM 2011Mile High500 HPDistinguishedTech CertifiedDonorAir Force
DIY - 2nd Gen Clutch Install
« on: November 30, 2008, 10:11:35 pm »
How to replace your 2nd gen clutch:

This is not a project to be undertaken by the backyard 'oil changer' - special tools and equipment make this job much safer and efficient.

I completed this swap in a shop with a lift and transmission jack.  If you don't have access to these, the job will be a PITA

Start by removing the center console and shifter:


remove the 6 screws from the shifter boot and slide the boot up

Lift the boot from the 4wd selector to access the hold-down bolt for the center console, remove all the hold down bolts (note - there is a bolt under the cup-holder rubber tray)

Remove the center console from over the two shifters (this requires a lot of wiggling and cussing)

Remove the bolts holding the lower shift boot to the floor

Remove the 4 bolts from the shifter base and remove the shifter


Cover the top of the transmission with a rag to keep contaminants out


Now - under the truck - I used a shop with wheel lift

Remove rear drive shaft (I marked the yoke and shaft with a sharpie for re-installation)


I removed the straps retaining the rear universal joint, then removed the two bolts holding the hanger bearing in place, then positioned a drain pan below the transfer case output seal and gently slide the drive shaft out of the transfer case and store out of the way.  Make sure you protect the splined yoke that goes into the transfer case from damage and contamination, and secure the rear universal joint caps from falling off.

Remove the front drive shaft (I only disconnected the front of the shaft from the front differential, and then left the shaft hang from the transfer case)  Mark the yoke as with the rear shaft

I did not remove the double joint from the transfer case:


Remove the skid plate from under the transfer case


Remove the steel lines supplying the transfer case (3 bolts)






Unplug electrical connector on top of the transmission (driver's side)


Disconnect vacuum lines on top of transfer case (single and 4 tube plug)


Disconnect transfer case linkage
This was very difficult - used WD-40 to lubricate the rubber bushing then pried out with large screwdriver

Remove clutch slave cylinder bolts and remove slave cylinder
When removed, the pushrod is under pressure - I used a wire tie to retain the push-rod


I supported the engine with a large jack stand under the oil pan, and positioned a transmission jack under the transmission


Secured the transmission to the jack with a ratchet strap




Remove the transmission crossmember and transmission mount (once the 8 bolts into the frame are removed, and the two bolts in the transmission mount, the crossmember needs to be slid to the rear of the truck for removal)

Remove the upper transmission mount to free it from the exhaust hanger

Remove the bell housing bolts, and remove the transmission/transfer case
This took some wiggling - had to lower slightly to clear the shift tower from the floor

no pics here - had both hands full 

Remove the pressure plate from the flywheel (8 bolts) - make sure you are supporting the pressure plate when removing the last bolt


Remove the flywheel from the crankshaft (8 bolts) leave 1 top bolt still in but loose
using a prybar, pry the flywheel away from the crankshaft then support it and remove the last bolt

Inspect the rear main seal


There was evidence of a slight leak on mine, so I decided to replace it

Drill two 1/8 inch holes thru the seal and screw sheet metal screws into the hole, then use a crow bar or claw hammer to remove the old seal


Clean the seal area, then install the new seal with the supplied installer

Follow the instructions included with your new clutch - below are the steps I took:

Install the new (or machined) flywheel, and use locktite (red) on the bolts - torque to 110 ft-lbs

Using the clutch alignment tool, hang the clutch plate on the flywheel

Install the pressure plate, and using a criss cross pattern, tighten the pressure plate bolts evenly (only go a few turns at at time to not distort the pressure plate)
Torque to 30 ft-lbs

Make sure that the clutch alignment tool slides freely then remove the tool


Remove the old throw-out bearing, and clean, inspect, and lube the clutch fork (at the pivots on each end, and on the flats that the throw-out bearing rides on)
Clean the input shaft of the transmission - especially where the throw-out bearing rides
Lube lightly the inside bore of the throw-out bearing


Reinstall the transmission:
Line up the transmission to the engine, and move forward gently - line up the input shaft to the clutch (most likely necessary to reinstall the shifter, and shift to 3rd gear so that you can turn the transmission input shaft by turning the output shaft by hand)

Move the transmission forward until the bell housing contacts the engine by hand - DO NOT try to pull them together with the bolts - BAD things will happen!

Install the bell housing bolts and tighten

Install the transmission crossmember and mount

Remove the transmission jack

Connect the vacuum lines and electrical plug

Install the clutch slave cylinder

Install the steel lines to the transmission crossmember and reattach

Install the front drive shaft

Install the skid plate

Install the rear drive shaft - I used a jack stand to support the hanger bearing while installing the rear universal joint

Install the transfer case linkage

Lower your truck and fully install the shifter, seal the lower boot and install

Install the center console and bolt down

Install the upper shifter boot, and the 4wd shifter boot

Check the level in the clutch master cylinder and adjust as necessary

Make sure transmission is in neutral, and start the truck

Depress the clutch, and shift to 1st gear, and slowly let out the clutch to make sure it engages

Follow the clutch manufacturer's recommendations for break-in




***Currently at Smokin Okie Diesel - Enid OK***
99 3500QCLB 6x6 5 Speed - D Tech Twins,SB DD3600,Adrenaline/Pulse,Smarty,DDP 110's,Hamilton's,ARP Studs,Airdog,CFE+,Silverline4",Mag-Hytec F/R,Amsoil-B2B,Isspro Performax Boost/EGT & Fuel-pillar mount,2Low Mod,BD SBS and Short Shifter, All LED


516/1127     9/18/09
14.788/93.78  8/8/09

If You Are Not Willing To Stand Behind Our Troops, Please Feel Free To Stand In Front Of Them!

Offline Cumminalong

  • Master of Destruction - Breaker of performance parts
  • Official DOF Vendor
  • Mechanical God!!!
  • ***
  • Posts: 25349
  • The BOMB'r
  • Awards:
    1100ROTYMember of the Year1 Tech
Re: DIY - 2nd Gen Clutch Install
« Reply #1 on: December 01, 2008, 12:28:51 am »
WHEW HEW!

Great write up!

Here's an Atta Boy to ya.

Offline mayfair

  • Master Smartazz!!!
  • Shade Tree Certified
  • Mechanical God!!!
  • ***
  • Posts: 19914
  • Last 8 - w j 1 8 7 6 2 5
  • Awards:
    rotm200k400 HPShade TreeContributorDonor
Re: DIY - 2nd Gen Clutch Install
« Reply #2 on: December 01, 2008, 09:44:29 pm »
AWESOME job !!

When's Drew comming up to have his done?

:43:

+1 on the atta boy click !!

Offline Kilch123

  • Regular Member
  • Mechanical God!!!
  • *
  • Posts: 10466
  • Thanks Pat and Adam!!!
  • Awards:
    DECEMBER ROTM 2011Mile High500 HPDistinguishedTech CertifiedDonorAir Force
Re: DIY - 2nd Gen Clutch Install
« Reply #3 on: December 01, 2008, 10:09:08 pm »
I made the offer - I work for   :drink: :cheers:
***Currently at Smokin Okie Diesel - Enid OK***
99 3500QCLB 6x6 5 Speed - D Tech Twins,SB DD3600,Adrenaline/Pulse,Smarty,DDP 110's,Hamilton's,ARP Studs,Airdog,CFE+,Silverline4",Mag-Hytec F/R,Amsoil-B2B,Isspro Performax Boost/EGT & Fuel-pillar mount,2Low Mod,BD SBS and Short Shifter, All LED


516/1127     9/18/09
14.788/93.78  8/8/09

If You Are Not Willing To Stand Behind Our Troops, Please Feel Free To Stand In Front Of Them!

Offline burban2002

  • Master Technician
  • ***
  • Posts: 1969
  • Awards:
    ContributorROTM
Re: DIY - 2nd Gen Clutch Install
« Reply #4 on: December 02, 2008, 04:12:45 am »
Awesome DIY Kilch.  How long did it take you?
Edge Comp thanks to JakeBrake

Offline Kilch123

  • Regular Member
  • Mechanical God!!!
  • *
  • Posts: 10466
  • Thanks Pat and Adam!!!
  • Awards:
    DECEMBER ROTM 2011Mile High500 HPDistinguishedTech CertifiedDonorAir Force
Re: DIY - 2nd Gen Clutch Install
« Reply #5 on: December 02, 2008, 03:29:44 pm »
Took about 5 and a half hours (including the run out to get the rear main seal)

I still haven't recovered yet - hands and arms sore from the wrenching (I ride a desk more than turn a wrench anymore)
***Currently at Smokin Okie Diesel - Enid OK***
99 3500QCLB 6x6 5 Speed - D Tech Twins,SB DD3600,Adrenaline/Pulse,Smarty,DDP 110's,Hamilton's,ARP Studs,Airdog,CFE+,Silverline4",Mag-Hytec F/R,Amsoil-B2B,Isspro Performax Boost/EGT & Fuel-pillar mount,2Low Mod,BD SBS and Short Shifter, All LED


516/1127     9/18/09
14.788/93.78  8/8/09

If You Are Not Willing To Stand Behind Our Troops, Please Feel Free To Stand In Front Of Them!

Offline mayfair

  • Master Smartazz!!!
  • Shade Tree Certified
  • Mechanical God!!!
  • ***
  • Posts: 19914
  • Last 8 - w j 1 8 7 6 2 5
  • Awards:
    rotm200k400 HPShade TreeContributorDonor
Re: DIY - 2nd Gen Clutch Install
« Reply #6 on: December 02, 2008, 05:30:31 pm »
Do you EVER do a job that doesn't require you to 'run out for parts'?

:lol:

Offline Kilch123

  • Regular Member
  • Mechanical God!!!
  • *
  • Posts: 10466
  • Thanks Pat and Adam!!!
  • Awards:
    DECEMBER ROTM 2011Mile High500 HPDistinguishedTech CertifiedDonorAir Force
Re: DIY - 2nd Gen Clutch Install
« Reply #7 on: December 02, 2008, 06:08:14 pm »
Seems like I just want to keep the local parts houses in business...

I hate it though - just when things are running nice and smooth, you find a leaky seal.

reminds me of that monkey joke:  "blew a seal"  :lol: :lol:
***Currently at Smokin Okie Diesel - Enid OK***
99 3500QCLB 6x6 5 Speed - D Tech Twins,SB DD3600,Adrenaline/Pulse,Smarty,DDP 110's,Hamilton's,ARP Studs,Airdog,CFE+,Silverline4",Mag-Hytec F/R,Amsoil-B2B,Isspro Performax Boost/EGT & Fuel-pillar mount,2Low Mod,BD SBS and Short Shifter, All LED


516/1127     9/18/09
14.788/93.78  8/8/09

If You Are Not Willing To Stand Behind Our Troops, Please Feel Free To Stand In Front Of Them!

Offline Mitch

  • Regular Member
  • Mechanical God!!!
  • *
  • Posts: 13015
  • Awards:
    500ROTMDonorContributorArmy
Re: DIY - 2nd Gen Clutch Install
« Reply #8 on: December 14, 2008, 06:32:52 am »
Good job on that man. You made it look easy. Any clue how different the 3nd gens are from the 3rd gen? I know the transmissions are different.
2022 2500 Laramie CCLB, 6.7 CTD, stock
57 Chevy 3200 pickup, 12V swap
1985 Jeep CJ10A former Tug- Dana 60, 6cyl Nissan diesel
2020 Mahindra Roxor, Dana 60s F/R, Ag tires

Offline spencea15

  • Shade Tree Certified
  • NASCAR Crewmember
  • ***
  • Posts: 3144
  • Awards:
    DonorShade Tree Cert
Re: DIY - 2nd Gen Clutch Install
« Reply #9 on: December 14, 2008, 06:57:19 am »
Good job on that man. You made it look easy. Any clue how different the 3nd gens are from the 3rd gen? I know the transmissions are different.

My gues is a 3nd gen is the same as a 3rd gen, :D
2000 Dakota CC slt plus, v6 :( auto.

Offline Kilch123

  • Regular Member
  • Mechanical God!!!
  • *
  • Posts: 10466
  • Thanks Pat and Adam!!!
  • Awards:
    DECEMBER ROTM 2011Mile High500 HPDistinguishedTech CertifiedDonorAir Force
Re: DIY - 2nd Gen Clutch Install
« Reply #10 on: December 14, 2008, 04:46:15 pm »
The 3rd gen is probably not much different from a 2nd gen.

I hope you have a shop to use - I think the transmission/transfer case would be a heavy mother to drop without a good transmission jack! (I think the NV5600 is even heavier than my NV4500)
***Currently at Smokin Okie Diesel - Enid OK***
99 3500QCLB 6x6 5 Speed - D Tech Twins,SB DD3600,Adrenaline/Pulse,Smarty,DDP 110's,Hamilton's,ARP Studs,Airdog,CFE+,Silverline4",Mag-Hytec F/R,Amsoil-B2B,Isspro Performax Boost/EGT & Fuel-pillar mount,2Low Mod,BD SBS and Short Shifter, All LED


516/1127     9/18/09
14.788/93.78  8/8/09

If You Are Not Willing To Stand Behind Our Troops, Please Feel Free To Stand In Front Of Them!

Offline 1995DodgeRam1500

  • Regular Member
  • Master Technician
  • *
  • Posts: 1004
  • Are you being served?
  • Awards:
    DonorNavy
Re: DIY - 2nd Gen Clutch Install
« Reply #11 on: December 14, 2008, 06:40:09 pm »
Any clue how different the 3nd gens are from the 3rd gen?

Let's hope you figure this out before you go to work on one.

Here's your  :dots:
« Last Edit: December 14, 2008, 06:42:30 pm by 1995DodgeRam1500 »
Slàinte

Ian

 

Questions, Concerns, Comments? Contact DOF Administrators
DodgeOwnerForums.com is not affiliated with Chrysler Group, LLC or Cummins, Inc