Engine/Transmission (1994 - 1998) Clutch

[zack_76401]

anybody got detailed instructions on replacing a clutch in NV4500?



Any help appreciated. .

 

[mikel]

Is your truck 2wd or 4wd?



2wd is alot easier as you don't have to mess with any of the front driveline or a transfer case.



The hardest part of it for me was the crossmember. The 2nd time I changed it out (long story) I made a metal brace to fit my jack and pushed the frame apart enough for the crossmember to come out easily.



Other than that, don't hang the transmission on the input shaft, get the flywheel turned *BY SOMEONE THAT KNOWS WHAT THEY ARE DOING* and consider getting some help moving the transmission around. It's pretty heavy.



Good Luck,

Mike



P. S. Where is Stephenville?

 

[zack_76401]

thanks but i need to know more about the shifter..... ie how does it come out and the hydraulic side of the clutch. . how do i pull the slave cylinder, how does it go back in ? i have never messed with hydraulic clutch before... ... . Stephenville is 65 miles southwest of FT. Worth down 377

 

[mikel]

Oh, ok. Now I understand.



I think the later trucks have a different mechanism that holds the shifter in, so someone will have to correct me if I am wrong on this, but on my truck there is a collar that you push down against spring pressure and rotate to release the shifter.



All I have seen on these trucks as far as slave cylinder goes is two bolts hold it to the transmission. Don't disconnect any of the lines just unbolt it and stick it back somewhere out of the way.



The slave cylinder just pulls straight out and will usually bring it's push rod out with it when it comes.



Hope this helps.



Mike

 

[zstroken]

don't turn the flywheel

You want to surface grind the flywheel. Very few places can turn it and not leave grooves in the flywheel

 

[SRadke]

To clarify a little...

The collar that you push in and turn is aroud the shifter where it comes out of the shift tower. Push it down, turn a quarter turn (CCW) and the whole thing, shifter and all pulls right out.



The slave cylinder does have two bolts and there is no need to disconnect the line but I believe it bolts to the bell housing, not the transmission. I'm sure you would have figured that one out.



One last thing. If you decide to change the transmission oil or drain it for any reason while it's out the easiest way to put the oil back in is through the shift tower before you replace the stick. Much less difficult than fighting gravity to get it through that little fill plug. Best of luck.

-Scott

 

[Deezul1]

The shifter comes out as described but is a booger to get that spring loaded collar to latch back in when putting it back. If any one has found a trick way to do this let us know as I think this is the most difficult part of the job. Spreading the fram to remove the cross member isnt needed, I watched the trans shop take mine out with no spreading and no trouble.

 

[SRadke]

I just ran across this thread:



https://www.turbodieselregister.com/forums/showthread.php?threadid=80163



Perhaps your 98 shifter is diffrent?

-Scott

 

[Briar Hopper]

I can confirm the 98 shifter is definitely different from the 94-97 version. The later model has 4 bolts that hold the shifter assembly to the shift tower. To remove the shifter, you need to remove the plastic cupholder console. There are mounting screws under the cupholder liners, under the lip of the shifter boot all around, and under the 4x4 shifter boot. Once you get all that removed, there is another shifter boot that is mounted to the floor sheetmetal, with screws all around the mounting lip. The shifter handle can be unscrewed from the shifter assembly. You may need a wrench to loosen it.

 

[zack_76401]

All right Thanks for all the replys..... now another LAST question... any tips on the pilot bearing and the throwout bearing installation? Special tools for the pilot bearing? what to check on as far as the input shaft while i have it out, etc?

 

[Deezul1]

A good way to remove the pilot bearing without special tools is to get a wooden dowl or any thing the right diameter to fit through the pilot bearing with out too much slop. Use a heavy grease or I use a bar of soap and start cramming it through the pilot bearing and packing it with the dowel. When it gets full start smacking the end of the dowel with a hammer and packing more soap in as needed and it will push the bearing slick as can be.

 

[mikel]

When you have the flywheel off to get it turned, just drive it out with anything that fits. I used an old socket to drive the last one out and a piece of wood to drive the new one in.



Mike