Engine/Transmission (1998.5 - 2002) Clutch install directions and pictures for 6 speed 4x4

[OO]

I took some pictures while installing my soutbend clutch a year ago planning on posting a how to segment on my website. Never got around to it and now I've forgoten quite a few things about the install. Take this as just a guide and not a step by step instruction manual. I'm sure everyone will jump right in if I get something wrong so here it goes.





Start inside the truck. With a phillips remove the screws holding the shift boot and slide it up.

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Remove shifter with 3/4" or 19mm wrench.

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Pop up transfer case shifter boot and remove bolt/s. Pull out rubber inserts in cupholders and remove bolt/s. Remove plastic shroud.

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Unbolt shifter boot.

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Unbolt shift tower carefully and tape clean rag in hole. If you drop anything into the trany like one of the bolts or a socket it's all over.

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[OO]

Now it's time to go under the truck. Unbolt the driveshaft and carrier bearing. Tape the caps of the U-joint together. Do not allow the slip joint by the carrier bearing to come apart. Remove the entire driveshaft as one piece.

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Remove front driveshaft,vacum plug,and vent hose.

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Pop out rod from transfer case at shifter.

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Unbolt clutch slave cylinder.

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At the top of the trans on drivers side is a wire loom that crosses over and is held down with a little plastic arrow stuck through a hole. Use a pair of needle nose pliers to pinch the arrowhead together then pull the loom out.

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Passenger side same thing.

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Remove electrical plug passenger side.

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Unbolt vacum hardline from crossmember and move out of way.

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[OO]

Unbolt fuel lines from frame on drivers side by crossmember. Support transmission with a good transmission jack. It weighs well over 300 pounds. Unbolt crossmember and with some big deadblow hammers pound it up being careful not to pinch the fuel lines. Pound it back to those big holes in the frame and it should come out. You can also use a hydraulic jack to spread the frame rails which makes it a lot easier. Use another jack or some blocks to support the front of the engine. Once the weight of the transmission is removed it will fall forward a little making installation a lot harder. Unbolt the transmission from the engine and slide it back then down. Alternate backing out the bolts on the pressure plate a little at a time. Once the pressure is released remove all the bolts leaving the top ones for last and be prepared to play catch with a very heavy piece of metal. The clutch disk will fall out once the pressure plate is removed so watch out for it also. Put some gloves on for the flywheel removal and place something like a sheet of plywood on the floor to protect it when it suddenly pops off smashing your fingers,toes,or whatever else gets in the way. Use locktite on the bolts when reinstalling the flywheel. A new pilot bearing should be used. Once it's mounted clean off all your greasy fingerprints with solvent. Remove the old throwout bearing. Clean the transmission input shaft and lightly regrease it. Install new throwout bearing.

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Install the clutch disk with alignment tool keeping your greasy fingerprints off the friction material.

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Install the pressure plate. Do not touch the side facing the clutch disk. Use locktite. Alternately tighten the bolts then remove alignment tool.

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Slide the transmission back up in place. Line the input shaft up with the center of the pressure plate and slide the trany forward. Adjust the transmission jack so the gap between the engine and bellhousing is the same at the top,bottom,left and right side. Wiggle the transmission in by hand. It may take an hour or it might slide right in on the first try. Make sure never to lower the trany jack and hang all the weight on the input shaft. It will destroy the clutch disk. The last hard part is to pound the crossmember back into place.





Well that's it. I think. At lest that's all I can remember. For now.





So many drugs... ... . so little time.

 

[Wiredawg]

Super Post

I've been contemplating doing this myself as I've done clutches on other vehicles I've owned. Did you pull the flywheel and have it resurfaced? How long did this take you?



thanks, Wiredawg

 

[Riflesmith]

Thank you for this timely information. I will be replacing my clutch very soon and will make good use of this information. This is definitely getting saved.

 

[OO]

Southbend said to resurface the flywheel or they wouldn't waranty the clutch. I had around 6000 miles on the truck but did it anyway to make sure the clutch would seat right and not slip. The install took 7 hours total. About 3 1/2 hours of that is actual wrenching. I had to go out of town to get the flywheel resurfaced which took 3 hours. The rest of the time was used up taking pictures and BS'n. If you've done clutches before it should take you between 3 and 4 hours the first time around.

 

[azcummins]

OO-

when you say use "locktite" do you mean red or blue locktite?

 

[OO]

I use the red stuff. Don't know which is better but the red seems to work fine.

 

[TxDieselKid]

if ya smell!!!!.........

Sounds like a TDR article to me, how bout yall?



Andrew

 

[azcummins]

Blue loc-tite will hold your bolts, but will let go if you want it to. (i. e. if you pull on it hard enough).



Red loc-tite will supposively never let go.

 

[FFL8N]

I just wanted to say thanks!! Great job and fantastic pictures!!!





Oo.

 

[d90boy]

Great write up man! The only suggestion I can offer is you can unbolt the shift tower without taking the center console out. I dropped the transmission down to where I could unbolt it from underneath. You just gotta be sure you get the stick in the hole (which I happen to be good at ) or else you'll be pulling up the console after the transmission is installed. The only thing that really works against the do it yourselfer is the sheer size and weight of the 5600 with transfer case. It takes a pretty manly transmission jack to handle the job. If you got that covered then you own it.

 

[rono]

GREAT info. and pictures. I know this took some time and we as members really appreciate it. I may have to be using these instructions before long and since I don't have a manual these will come in very handy. I copied and pasted into Pagemaker text and photos. Thanks again, Ron

 

[FFutch]

A hoist is nice too. I did mine on my back. Still wasn't too bad with t

he truck being a 4x4. Good job on the pics and write up... Doug

 

[jhurst]

TTT



nice pics Oo.



good info for anyone preparing to install their own clutch.



Justin H

 

[MDale]

I was wondering what everyone uses for a transmission jack if you do the job on the ground(no lift) on a 4X4? I'm going to need a clutch soon and don't think my floor jack w/ trans adapter will reach the 5600.

 

[azcummins]

I always just went out and rented one from the local rental (Best Rental/United Rental, etc) shop. Theirs always worked fine for me.

 

[RHARVEY]

Do you remove the transfer case and then the transmission? I am getting ready to do a 4X4 and would like to know how to do that one. .



Rick

 

[AndyMan]

I usually just leave the tcase connected to the transmission. If your working with a lift and a transmission jack, it's no big deal. If you are doing it on the ground, you might want to take the tcase off first and then the transmission.