Engine/Transmission (1998.5 - 2002) 99 5spd clutch issues.. ?? opinions??

[David_VT]

UPDATED 7/17: New one piece hydraulic assembly installed in my driveway. LIFE IS GOOD AGAIN!



UPDATED 7/15: Limped truck home without a functional clutch pedal. I was in traffic coming to a stop at a traffic light when the clutch simply refused to dissengage. Suprisingly, the engine stalled when I locked up the brakes. The guy in front of me had no idea how lucky that was for him... .



I was able to then start the beast in first gear on a hill and had to 'speed' shifted all the way home. . a bit hairy but I got it home without any close calls. . I think the 3rd gear syncro lost a few years on this one... .



$206 for the 'hydraulic unit', waiting parts, will attempt to replace myself...

Pedal will not come up smoothly on it's own and has no effect on the clutch friction whatsoever. Fluid full but I hear a 'squishing' sound when I press the pedal now...

Wish me luck...



Hello all,

My clutch pedal engaging position is starting to toggle from the top of the pedal (normal) to near the floor or not at all. No pattern, hot, cold, etc. Sometimes three times in 10 minutes and then not for days and days... . Twice I could not get the truck into gear at all while turning around in traffic.....

Once I almost hit a car in a parking lot when the clutch would not release (and my cummins does not obey the brake pedal at all. ... )



The green monster is a 99 5spd 2500 with the JD SACHS Clutch, some HP toys including the smarty and is slowly starting to show the years of hard winters and rough roads... . At 140K I still love the beast but problems are becoming more and more frequent. I will get it past 200K if I have to drag it there with my 55 powerwagon!



Latest issue, looking for feedback before I buy parts:

Since I installed the JD SACHS Clutch, many moons ago, I've never had clutch problems. All kinds of abuse and she just kept going. That clutch is very much a truck clutch and would grab at the top of the pedal throw. I have been very happy with it (once I learned how to use it)...



About one month ago after driving from Vermont to Detroit, the beast acted like a bull in a china shop when I was starting to leave one of those millions of big city traffic lights. (maybe one within 20 miles of home )



The clutch engaged just off the floor and the truck leapt forward so hard we just about rolled our heads over the seat backs... . It did it a few more times on that trip and I just blamed it on city traffic and was quite happy when I got back to 'the sticks'. (And no, I don't sit at the lights with my foot on the clutch at all. )



Unfortunatly when I visited our state capitol a few weeks ago (maybe 6 traffic lights?)... I was doing a three point turn in the middle of a busy road and the 5 speed would not go back into any gear... . Finally after enough stirring and cycling the pedal, I got going again. A few moments later when I pulled into a lawyers office parking lot, I almost bought his bimmer as the clutch would not release. . Oh that was scary... .



So, sorry for my usual long winded post. I think my slave cylinder is going but I don't understand the intermittent operation symptom. I have never added fluid to it. I have never seen the level change from what it was when I bought the truck.



Could it be anything else obvious or should I drop the $300 for a new assy. Thank god it is on the outside as it does not look like to bad of a job.



Thanks for any input...



David in Vermont

 

[David_VT]

just bumping up for any possible feedback, thx

 

[rubberneck]

Mine went at 90K and gave absolutely no indication that there was a problem. I had been towing my 35ft goose neck all day and when i got home, i went to park and pedal went all the way to floor. thank god i was not pulling it into the garage where i normally park if i had not had the trailer on. I had only been in the new house for about a month, and it would have taken out the water softner :{ The job to replace is pretty much a snap. I had more difficulty fishing the old one out cause i had some wires zip tied to it and whatnot. the new unit is in 2 pieces, but is pre-bled with a coupler in the middle. just install the 2 pieces and push the hydraulic coupler together and you are good to go. 30 min job max.

 

[David_VT]

JOB DONE!

I got a one piece unit for my order. It went in fairly well. . Nuts did not come off the slave studs but the stud did back out of the trans housing without bringing any metal with them. Not having any locktite I will have to go back and seal them up later.



The one body clip fell apart when I tried to remove it. I'll have to get one in the near future so friction does not ruin the line.



I was not sure if I should leave that plastic clip on the slave (to prevent the piston from coming out in shipping). I decided to leave it on as I read that was appropriate for slave only installations.



The engine compartment modifications over the last 7 years did make removing the one piece unit a bit of a struggle. I guess proper planning back then might have made this easier... .



SO, I finished bolting it all up (no lost parts, amazing), remembered to plug in the wiring harness, put the beast in neutral pressed the clutch, cranked it up and easily found reverse... ... AH, LIFE IS GOOD AGAIN.



SO, for the moment, the green monster rides again..... but for the inspections sticker, lack of parking brake, probably toasted back brakes from PB locking up in the winter, and rear axle seals... .



BUT, SHE STILL GOES LIKE HELL!!!