Engine/Transmission (1998.5 - 2002) Bad shifting and noise after clutch install

[ILIANBG]

I am experiencing really bad shifting with the engine on, and when start driving- noise and vibrations, like something is loose. I'm afraid of driving it and damaging something.

It all started because 1st and Reverse were a bit hard to get into. It would go, but after 2 try usually. No force, just harder shifting into those gears. Fluid is changed every 30000 miles-either dealer fluid or Pennzoil Syncromesh.

After a lot of researching and talking to people, the opinion I got was- bad pilot bearing. I do get in bad traffic often, so a lot of shifting. There was never any noise or vibrations. Clutch has never slipped. Truck has 108000 miles, I bought it brand new.

Few months back I found a leak inside the cab, coming from where the clutch master cyl. enters the cab. I ordered the SBC hydraulics. It was good when I started the truck, and I thought my problem was solved. But later the shifting was the same.

So- after the research, the pilot bearing diagnose came out.

I decided, after recommendations here, to get the SBC ConO with the upgraded pilot bearing and new flywheel. It's expensive, but I wanted the best, that's why I bought it.

I ordered it and had it installed at a diesel performance shop, specializing in diesel Dodges about an hour drive from me.

After the install the owner drove it from the back of the shop to the front and told me it shifts hard, but "once running shifts fine" What an answer! I told him I will not drive like that.

I sad it's not good, it was way worse then before.

He said from around 50 SBC they've installed mine was the 3rd with such problems after install- that's a big percentage! He said after another new clutch was installed, it was fine. So, after talking with Peter he's sending new parts to them, so I have to drive and hope to get it fixed. How frustrating. What if something was damaged during the drive home or when I have to go back to them?

So, now I'm suspecting that the new SBC hydraulics are not pushing far enough on the fork to release. Maybe there is trapped air inside. It supposed to be pre-bled, that's what I was told when I ordered it. How do you bleed it?

Sorry for all that. The questions is: Has anybody experienced this after a clutch install, specifically after a SBC ConO with their flywheel and new pilot bearing?

By the way, my OEM clutch was almost like new after 108000 m. The flywheel too, the pilot bearing looks a bit dry, but not damaged, spins fine, all the needles are there. I do not know what it's supposed to look like. All the parts seems perfect. The owner of the shop said-"nothing wrong with any of the parts-they were in very good shape".

Thanks again, and sorry for the emotions. It's just frustrating, that I can not work and have to sit home from last Friday 25 till Tuesday 6. I'm not getting paid, I'm self-employed.

I would like to see if this has happened to anyone and what was the couse.

I'll let you guys know how it turns out.

Ilian

 

[PC12Driver]

I just put in a Con-OK this past weekend, and I'm still trying to re-learn how to drive it because it is so much smoother than the OFE it replaced. Easier shifting, too. Your case is probably an installation error.



The hydraulics shouldn't need to be bled, and are probably just fine. There are two things that I'd look at, and unfortunately they're behind the clutch disk. First would be the release arm. It can be mounted backwards (slave cylinder side on the pivot ball), but it won't release the clutch properly if it is. Second, the clutch kit comes with a washer to install behind the pivot ball to change the geometry to bring the engage point a little further off the floor. If they didn't put that in, you could still be dragging a bit.



Hope you get it worked out soon. You'll be very pleased with that clutch when you do!

 

[ILIANBG]

PC12Driver,
Thank you. I'm happy to see it works well for others. I really hope to have it working properly. Did you install it yourself?
I wanted to have it installed by pros, that's why I drove an hour.
We'll see after Tuesday. I will post what happens.
Ilian

 

[PC12Driver]

Yep, it was a self-install.



Just thought of another thing you could try - adjust the clutch linkage. The SBC setup has a threaded rod going into the master cylinder. If you unclip the linkage from the pedal, you can back it out a few turns to gain some pedal throw (resulting in more slave piston travel). I left mine where it was with the OFE, which was several turns out from as-shipped.

 

[ILIANBG]

The shop tried this. It's pretty high. Higher than before the clutch install. They said it did not make a difference. I'll find out on Tuesday.
Thank you.
Peter is being really nice to ship new parts and cover for the second installation and shipping.
I'm glad I ordered from them.
Ilian

 

[DMcLeod]

I had the exact same situation. I put in a Con OFE w/flywheel last fall, and it flat wouldn't shift. Tried a few new hydraulics with no change (it needed to be actuated farther than the hydraulics could push in order to disengage), so sent the whole works back. Second set worked. I never did get an answer as to what was wrong with the set I returned - my email was ignored. I was down for 2 months monkeying around with that junk, renting jacks and all. What a pain - and never compensated for my additional time and cost even tho they said they would. Sure wasn't the experience everyone else brags about on here. This aint rocket science! A non-adjustable hydraulic actuator and the rest is just replacement parts. My original parts were same as yours... . the pilot was a bit dry was all, but it was getting very difficult to shift (mainly 1st & reverse). In fact often you couldn't shift it directly into those gears. New hydraulics did not solve that (just as in your case), and so I replaced the clutch thinking the pilot brng was going. I also put in the new ball, lever, added washer under the ball, etc.



To give SBC credit, I enjoyed working with Peter and Mansiel and learned a little about clutches as we went along. They took care of me, sending/exchanging parts until I was back on the road. I'm told they have excellent quality control, but, like you, this isn't the first I've read about on here or other forums, so go figure. I hope you get yours back on the road soon.

 

[ILIANBG]

So, today it was fixed. Thanks to Peter and his company- they sent the new parts-flywheel, clutch disc, pressure plate, probably new bearings too, the owner of the shop said all new parts. It drives normal again- no noise, vibrations, bad shifting as before.
The shop said I had excessive wear on the input shaft, maybe that's why there were the noise and vibr. After the new parts were installed - it drives fine. 1st and Reverse are notchy as before, but not worse. So, I do not know what is the reason, but I will start saving for transmission work.
So, again, thanks to Peter at SBC for getting me back on the road. He was very helpful and patient, and took care of the issue.
It's a good company, building good products, and trying their best to help their customers.
Ilian