2nd Gen Non-Engine/Transmission Difficulty in changing clutches??

[C. Harlan]

I have a question... . I am wondering how hard it is to drop the "bolt action" (5 speed) transmission, and changing out the clutch... is this an all day affair, or something that is going to take an entire weekend? I know some of y'all have done this before, and so I need Y'all's input on this... I am getting a CON OFE clutch here within a month, and need to know if I need to have a transmission dropping party and provide the beer, or if it can be done with just 2 or 3 people... . Please write back and let me know... Thanks,



-Chris

 

[Deezul1]

With 1 good helper its 2-3 hours. The hardest part is the shifter reinstall and the cross member R+R. Stretching the frame for removal of cross member seems to be required but 1 member told of another way so hopefully he will see this and speak about it. Definatly need a trans jack that mother is heavy.

 

[gitchesum]

We did mine in a few hours. That included a lunch break, beer breaks, and BS breaks.

There were 3 of us under there. We didn't use the frame spread method that some have, we just beat the bejesus out of the cross member until it came out.



Clutch install went great overall. I got a bunch of pictures of my install if ya wanna check them out. I'll post them on the net if ya do.

 

[Steve St.Laurent]

Like said above it's a few hour job. You'll want two people and a transmission jack to do it. The thing that takes the longest IMO is taking the interior apart and putting it back together. The cross member is really easy to take out if you know how to do it and you definately don't need to spread the frame. Here's how, attach the transmission jack to the transmission. Unbolt the transmission mount from the cross member and jack the transmission up slightly. Then remove the transmission mount from the transmission. Now take the cross member bolts out and unbolt the hardline to the transfer case (if you have 4x4) and also unbolt the fuel line holder on the drivers side of the frame. Use a sledge or a rubber mallet and hit the cross member on the bottom on each side to drive it upwards then simply pull it out. Installation is the reverse. The cross member is V shaped where it attaches to the frame so if you hit it upwards it will then slide right out.

 

[C. Harlan]

WOO HOO!! The heck with paying someone to do that! I have a jack, I guess I need to either make a transmission mount, or just get one. . I am looking forward to getting this clutch installed! If anyone else has any other tips, or input, feel free to write. . I will be checking this thread... Thanks y'all for everything so far!



-Chris-

 

[JLinder]

Good transmission Jack is Key

I just put a Con OFE in my truck a couple weeks ago. I had one of my buddies help me, and it went pretty good. Steve hit it right on about the cross-member removal, I didn't figure it out until we were putting it back in. I just took a couple of small ratchet straps to secure the transmission/transfer case to the jack, and it wasn't to bad. Only bad thing is there isn't a lot of room between the transmission and the floorboard, which makes removal of the transmission and installation a bit of a challenge but it's not any worse than any other clutch jobs I've done.





Good Luck!

 

[bighammer]

I rented a transmission jack for $20 for the weekend. It's a heavy monster. The security of a quality setup is reassuring when you cwawl under there. The multi-axis tilt was nice too.



Line up somebody to turn your flywheel. I found most shops are closed (or close early Sat) on weekends.



Steve is right on the crossmember. It's sort of wedged into the frame and bolted.



Check the clutch operation after you get the first couple bolts in. My fork slipped and got bound up on something. Didn't find out till I had a lot more bolts in

 

[C. Harlan]

Is it a MUST to get the flywheel turned??? I think with enough full throttle at this time, I am making a new grabbing surface with all the power I am making now! hehe... Just thought I would ask... I am going to get some shops lined up that are open on saturdays though... . Thanks for all the input, and keep the replies rolling in... I promise when all is said and done, y'all will have some pretty numbers on the signature that will make you go :--) !! Anyways, talk to y'all later!





-Chris-

 

[QRTRHRS]

Chris, listen to the experts. Do the flywheel. Spring for a serious jack. Might want to grab some rubber fuel lines. Good time to replace them with the bellhousing out of the way.



Re: crossmember. Pop it up and slide it backwards. Comes right out.

 

[OO]

This thread should help you out a little.



Clutch install with pictures

 

[bighammer]

Replacing fuel lines? I wish I had thought to do that

 

[Oxjockey]

In regards to resurfacing the flywheel, I was under the impression that you had to do it to keep your warranty on the clutch valid, FYI.



Bryan

 

[RHARVEY]

I did the 13" CON O FE upgrade on my 97. . The kit comes with the flywheel machined and ready to go. All the parts are there and ready to be installed. Sweet setup and the 13" in the 5 speed works great.



Rick

 

[GGill]

Rear main seal too!

Just did the South Bend Con OFE switch as well...

Some wise person posted a few months ago about doing the rear main seal at the same time... very good advice indeed.



About $60, and 15 min. of time if you read the directions that come with the seal.



Good Luck, Greg

 

[mikel]

On another vehicle that I worked on once when I had the flywheel turned I had to replace the flywheel bolts as they were apparently torque-to-yield. Can we reuse the flywheel bolts on our trucks, or do we need to replace them?



Thanks,

Mike

 

[Steve St.Laurent]

The service manual says to replace them - I did. I also had my flywheel resurfaced with the type of stone that was recommended by the clutch manufacturer - there are different ways to resurface a flywheel, make sure to use the recommended method.

 

[RHARVEY]

If it were to do over again. . I would order the input shaft ,bearings and seal. When I did the clutch job I replaced the throw bearing fork.



Rick

 

[QRTRHRS]

Originally posted by Steve St. Laurent

The service manual says to replace them - I did.

Replace the bolts, hummm. O'well.



Re: fuel lines at the same time. Cuts the job to being a half a pain in the butt.