Clutch Install "How-To Guide"... anyone wanna take a stab?

[SLightfoot]

Well, I have my new South Bend Con O clutch and resurfaced flywheel sitting in their packing boxes at home.



My uncle and I plan to do the install on my '99 2500 April 1st.



I have never installed a clutch before, but tackled many other serious mechanical issues before with success.



So, seeing as how some of you will have done this before, anyone want to take a stab at writing a "How-To" guide and post it here. Something to follow step by step that will help avoid making any mistakes along the way?



Any takers?



Shawn

 

[SmokinJoe]

Originally posted by Shawn. L. Turbo

anyone want to take a stab at writing a "How-To" guide and post it here. Something to follow step by step that will help avoid making any mistakes along the way?

I think the TDR should have How-To guides just like the Linux guys do. These are very good guides and have revision levels as well as maintaners...

 

[Cobra]

how to guide

Shawn,

Let me jump in here to say that I have never changed a clutch in a RAM 4x4 but I have changed a few in cars over my lifetime. The first step is to be sure that you have a shop manual. You will need that regardless of any other instructions you get. IMHO

 

[SLightfoot]

BUMP

OK, since no one took a stab at writing instructions, maybe someone could make a list of tools and things required for the install to go smoothly.



Anyone?



Shawn

 

[Texas Diesel]

https://www.turbodieselregister.com/forums/showthread.php?threadid=37544

 

[SLightfoot]

Thanks for the link, but since mine is a 5 speed, how much of this will be the same?



I would assume most, but anyone know of any major differences (aside that the clutch itself is a different size)?



Shawn

 

[bighammer]

An uncle who has done a clutch before would be a great tool. It's been a while for me, but I will try to remember.



Basic mechanics tools (sockets and combo wrenches, etc. )



A transmission jack is a must.



A jack and jack stands (needed to get the truck high enough to get the trans out of the way)



The jack will also be used to raise the trans to remove the rear X-member (after removing mount from trans and x-member raise trans and move x-member up, back, down and out)



A "pickle fork" or ball joint separater is handy for removing shift lever. I tightened a crescent wrench in the shifter stub flats and one under the shift lever drove the fork between them and it came right off. (don't buy the special puller)



I removed transmission and transfercase together. It was a tight fit and not worthwhile. Follow the book for removal sequence. BTW don't tilt either one when they are out. they will leak oil and make a nasty mess The mix of the two fluids w/kitty litter make unique patterns on your garage floor when a creeper is roll thru repeatedly.



It's dirty and time consuming, but the satisfaction of having done it yourself is priceless. Just go for it. E-mail or PM me and I'll give you my phone number. If you have any other questions, before during or after, I'll be happy to try to help.

 

[Deezul1]

Get some Castrol Superclean in the purple 1 gallon jug and spray everything underneath heavily and then wash it off and repeat. Be sure and wear rubber gloves and goggles as this stuff kicks butt but will hurt ya if ya aint keerful. If you have access to a Porta Power to spred the frame a little the crossmember comes out easier. The kevlar pilot bearing is not needed unless you have a problem input shaft just use the needle bearing one.

 

[SLightfoot]

Nice pics

Whoa, I just spent a few minutes carefully reading the post of the link that "OO" posted on the 6 spd clutch install.



Nice pictures... such great detail.



Certainly gives me a better idea of what I'm in for BEFORE taking it apart.



SB Con O goes in on Friday!!!



Shawn

 

[M Barnett]

Heres the only problem I ran into that hasn't been mentioned. The throw out bearing runs in a crossbar that runs from one side of the bellhousing to the other. On the passenger side of the bellhousing it is only held in place with a small spring until everything is bolted down. After getting everything back together, one of the last things to do was connect the clutch linkage to this throwout bearing crossbar and I discovered the other end fell off. Was sure considering cutting a new hole in the bellhousing to place it back in its socket when it went back in the socket while working the other side with pliers! The next time I do this I will check as soon as I get the transmission stabed to be sure its in position. Anybody else have this problem. Take your time and don't force anything.

M Barnett