Engine/Transmission (1998.5 - 2002) Clutch replacement tips?

[Arkansas Traveler]

As predicted my clutch is slipping badly after some recent mods. I'll be laying on the ground with a motorcycle/atv jack to pull the nv4500 trans. Anybody got any tips? Can I unbolt the shift tower from below or is it easier from above? My clutch choice is the SBC Dynamax 13" Con OFE. Thanks... .

Glenn

 

[DSeamans]

I've got the 5600, but take the shifter out the top. Take the boot off the shifter and work your way down. Its pretty easy. Make sure the jack will work under there. For me it was too big to work with. I made a cradle for my 4 ton high lift floor jack. Make sure to strap it good. Build in some pivot so you can move the transmission around on the jack. That helps get it up in the space and movement to line up pilot shaft/bushing. BTW, my 5600 was too tall to roll out from under the truck without putting it up a few inches on jackstands. Its also nice to be able to sit up under there to work. Get the new flywheel with the clutch. Resurfacing just isnt worth it. South bend gives a really good deal on the package.



Good luck,

Dave

 

[Arkansas Traveler]

Thanks Dave, Thats the info I was looking for. Changed many a clutch over the years, but that trans is pretty big and I'm older (wiser?) and appreciate the info...

Glenn

 

[lholley]

I had a 95 gas truck with a NV 4500and the only help I can be is the shift lever is "O" ringed on to a short square stub shaft. Take the shift boot off and with a long screwdriver the lever will pop right off. The stub shaft doesn't come off.

Larry

 

[BDaugherty]

I just installed the OFE into my '01 6spd 4x4. It was a decent job, but not too bad. I had to take the console and shift tower off from in the cab. I drained the t-case to minimize how much oil dripped onto the shop floor when I pulled the rear shaft. I didn't believe how hard it would be to get the crossmember back in until I actually tried to do it. I wound up using a 25 ton ram and a block of 4x4 wood to spread the from until it slipped back in. The main thing is to carefully removed everything so that it goes right back together. Use a torque wrench and lock-tite on the flywheel and pressure plate bolts. Be very cautious and gentle going back in with the trans. You only want to do this once. I've got right at 200 miles on mine and it's just now getting broken in. If I had it to do again, I would still do it myself. I used a floor jack with a home made adapter to hold the trans. It took as long to build the adapter as it did to pull the trans. On my 4x4 with 315's, I didn't need to jack up the truck or anything. This is also a good time to replace any leaky seals that will be easier to get to with everything apart.

 

[JesseJ]

While you have the transmission out, pull the top cover off and the 4 bolts that hold the input shaft bearing. Then you can pull the input shaft out the front of the trans and replace the small bearing that sits inside the input shaft. That is the front bearing for the mainshaft and is pretty small for that much torque. It might keep you from having to pull it later because that bearing went bad and chewed up the mainshaft, requiring replacement of the mainshaft. It happened to me, just a thought. The bearing probably isn't too expensive and it's cheap insurance. Easy to do since you already have the trans out. Just make sure none of the 3-4 syncrhos fall off or out of place when you pull the input shaft out.

 

[JPulliam]

Where do you get that bearing?

 

[JesseJ]

I got a complete rebuild kit from Dan at Quad 4x4 but I'm pretty sure he sells all the individual peices. Look on their website for the NV4500 or contact him directly -- email address removed --. He is a great guy and has always been very helpful in answering any questions I had and they sell quality parts. Your other option is to find a shop near you that's a New Venture dealer. They can probably come up with the bearing.

 

[JPulliam]

I looked all over last night, and did not see it. I saw their wide selection of pilot bearings, though. Did you use one of the over sized ball bearings?

 

[JesseJ]

Maybe find a shop around your area that sells medium/heavy duty parts. If they can get a parts manual for the NV4500 they can get that bearing. I guess your other choice would be go to Dodge. I know dealerships are pricey for parts but that small bearing might be halfway reasonable.



I did use one of their ball bearings for a pilot bearing, took my flywheel to a local machine shop to bore out the center of the flywheel so it would fit. It worked fine but I didn't have the transmission that long after I rebuilt it. After turning up the power I was slipping the better than stock clutch I had put in it and just decided to bite the bullet and get a 6-speed for a beefier transmission and bigger clutch.

 

[JAlford]

Glenn - if you haven't already done so, check the axial movement of the input shaft before pulling it out to replace the needle bearings on the end of the mainshaft that were mentioned earlier. If you have more than the . 006" of play, you will at a minimum need to check the 5th gear nut on the output side of the transmission. Don't know if you have the upgraded mainshaft or not, but either way, you will need to check it out. If the nut is still tight, but the end play is excessive, then the bearings are worn, and you will have to make a call if you want to risk it and shim the bearings or just rebuild the transmission.

Remember to purchase new bolts for the flywheel and input shaft bearing housing, replace the rear main seal if it is leaking at all or has a lot of miles, and check the aluminum tailshaft housing (5th gear cover) for any cracks.

Suggestion on the jack - I use an ATV jack also. Purchase a pack of door installation shims at a home improvement store to shim under the transmission to get the angle correct for going back in. I raise the rear axle up on jackstands so that the transmission is level, or fairly close, to make it easier to get the alignment correct.

Thanks,

Jeff

 

[Arkansas Traveler]

Hi Jeff, I just finished puttin her back to together. I did check the input shaft and it was tight but I didn't feel like taking the transfer case off to check the 5th gear nut. The trans has shifted just fine so I figured taking the chance it would be fine for now anyway. When it turns into a pile of greasy parts on the road I'll regret not checking it when I had the chance.

Glenn