Engine/Transmission (1998.5 - 2002) Crossmember surprise

[Ponz]

Had to change the clutch this weekend and really had fun with the crossmember. Used a small scissor jack and a 4x4 to get it out. While it was out I measured and distance between frame rails was 31", but crossmember measures 32". Trip to rental store for a portapower was more than worth it.

I've removed a few crossmembers before, but never seen a frame in compression like this. Is there a logical reason for this. Ponz

 

[DCreed]

was the truck on a lift? how was it supported?

 

[JacobsD]

I ran into the same issue when I did the clutch in my friend's 00 6 speed last week. It was ridiculous horsing around with the porta-power until the crossmember slipped in there. My 95 was nothing like that #@$%!

 

[Arkansas Traveler]

I had the same thoughts about the crossmember when I changed my clutch.

Take a second look at where the crossmember sits in the frame. That area has a slight V shape to it. The crossmenber is supposed to be wider at the top. It takes a bit of wrestling to get that thing back in past the transfer case.

 

[Spunkys Ram]

Exactly what Arkansas Traveler said. The crossmember is in a wedge, the more weight you put on it, the more it pushes againsit the the frame so it does not soely rely on the strength of the bolts alone. It's no different on an AUTO, I know. I think it's a very wise idea myself, however if you don't know, then it's a PITA... but now ya' know.

 

[Ponz]

Truck was in the driveway with jackstands at both ends. Just high enough so I could sit inside the trans hump and lift that 53 lb flywheel into place. Guess I'll go visit the chiropractor soon.

 

[GCroyle]

We have installed a bunch of NV4500, NV5600 units and never used a hydraulic jack to spread the frame. When you get the trans supported, mount is removed, work the X-member UP to the bottom of the cab, then start tapping it out to the rear, side to side keeping it UP as high as possible during the process. Installation, we clean off any rust, position the X-member UP and start working it forward, get it close, position mount, use line up drifts to get the holes in position, work it into position. Yes, we do tap it with a machinists hammer, but it is not log splitting swings, just giving it the idea where to go.

 

[Mad Bomber]

When doing clutch I used a little bottlde jack and a 4X4 with explosive results. It fell out and thank god that all 3 of us doing it were albe to get out of the way before it came out.

 

[GCroyle]

That could have gotten REAL ugly, glad you guys dodged a Jack!



Oh, nice addition to the tools for this job is ear protection, you bang on the X-member, it's sorta loud.

 

[Mad Bomber]

That could have gotten REAL ugly, glad you guys dodged a Jack!



Oh, nice addition to the tools for this job is ear protection, you bang on the X-member, it's sorta loud.

We had about 1 second notice of pending collapse and rolled away for area. Of course this was a clutch change done on ground with wheels on jacks. The other people at BOMB party came rushing over to see if everyone OK.

 

[Arkansas Traveler]

Here is a photo for the folks that are wondering what we are talking about.

You can see the taper of the frame where the crossmember sits. It is ahead of the transfer case. The rear crossmember looking thing is the rear support for the skid plate. You can see a hole in the frame just behind the trans crossmember and there is a hole just like it in the opposite frame rail. Use these to walk the crossmenber up the frame rails past the transfer case. It still took several firm raps with a decent hammer to get it all together. Hope this helps you guys... Glenn

 

[cummins82]

At least you guys had help

When I changed out the clutch in my '02 last January I did the work by myself in an unheated, uninsulated shop with a hi-lift to spread the frame enough for me to work the x-member back with a 5 lbs. sledge =P I actually froze to the floor of the shop one night!

 

[Mad Bomber]

At least you guys had help



When I changed out the clutch in my '02 last January I did the work by myself in an unheated, uninsulated shop with a hi-lift to spread the frame enough for me to work the x-member back with a 5 lbs. sledge =P I actually froze to the floor of the shop one night!

Your lucky to have a closed garage, my garage is the street. I can't even do it in the driveway because it's at to much of a angle. On a creeper you would be shooting out to the street in a real hurry.

 

[GCroyle]

True story, sorta related to the "horror" stories posted above.



A couple of years ago I was visiting an account in Goshen IN and a BIG guy comes in looking for a solid flywheel system to replace the DMF that he was taking out of a Ford 7. 3, OK so far so good. I asked a question or two, the old DFM was so worn out, this guy WELDED the two sections together to make a temporary solid out of a DMF, that's GET R' DONE down and dirty. Next I asked what the truck was used for, turns out it was a tow rig for a traveling circus, OK, so where are you doing the job, the BIG GUY replied out in the field on his back, no jack, just tools. After I recomposed I asked if he was the "Strongman" for the circus, nope, just the driver, rigger and fixer.



That's a one tough guy!

 

[Mad Bomber]

True story, sorta related to the "horror" stories posted above.



A couple of years ago I was visiting an account in Goshen IN and a BIG guy comes in looking for a solid flywheel system to replace the DMF that he was taking out of a Ford 7. 3, OK so far so good. I asked a question or two, the old DFM was so worn out, this guy WELDED the two sections together to make a temporary solid out of a DMF, that's GET R' DONE down and dirty. Next I asked what the truck was used for, turns out it was a tow rig for a traveling circus, OK, so where are you doing the job, the BIG GUY replied out in the field on his back, no jack, just tools. After I recomposed I asked if he was the "Strongman" for the circus, nope, just the driver, rigger and fixer.



That's a one tough guy!

:--):--):--) That's so strange I don't think you could make it up even