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how hard is it to change a clutch?

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i am thinking about taking this on myself. I just wanted to get an idea about it. Will this be worth the saving? or should i just pay someone?

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(Silver Bullet)1999 Ext Cab 4X4 5SPD, All options. Power Max 3(adjustable), K&N Filter, no muffler, Pyro,Fender Flares, Toolbox, bedrail covers, 450 watt Kenwood Sub, 33 12. 50 16. 5's, 3. 54's... Soon to have: 4inch, DDIII's, Southbend clutch.
 
It's not hard to do... just takes a long time. Me and jmbrowning did my 6spd at my work,on a lift rack with air-tools and a transmission jack and it took us 6-1/2 hours. The hardest part was getting the trans crossmember out from between the frame.
It's hard to say wether I'd recommend someone to do it themselves. I myself wouldn't do it laying on my back in a driveway,especially when you really need two people to do this (the clutch and flywheel weigh over 54 lbs each,and how about pushing that trans back in!).

If you've got time,a warm floor and an extra car,then... .

-Mike

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'00 2500,QC,4wd,LWB,Dark Garnet,6spd,3. 54lsd,SLT,DD stage II,Psychotty air,10-level PM3,Jacobs ebrake,Isspro pyro & boost gauges,2wd-low,Airoquip fuel lines,Smittybilt nerfs,BFG 285/75 AT's
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'95 2500,Reg-cab,2wd,LWB,White/Star silver,Automatic,3. 54,SLT,Michelin 265/75
 
The only difficult part of the job is the crossmember. You will need to spread the frame to remove it. I'd suggest either renting or buying a port-a-power, as the jack and 2X4 method can be dangerous. I just did mine this past week and it took about 4. 5 hours to do it on the ground. Having a adjstable transmission jack makes the the job alot easier. One other thing to do is when reinstalling the transmission, jack the front of the motor up so there is a good angle between the two and there will be enough clearance for the shift tower. Doing my transmission reminded me why I got out of the transmission business
 
I watched and sort of helped someone do his. Not bad, some potential pitfalls if you are not careful and don't have good instructions (don't touch the clutch pedal until you are finished finished finished). He rented a transmission jack which made the job less intimidating.

I paid to have mine done due to time contraints and lack of an enclosed garage. Also some potential pitfalls when you are concerned later if the job was done correctly since you don't get a chance to see every step.

Bottom line, if you have the time tools and mechanical experience, go for it. If not, find a shop you trust, bite the bullet and write the check. Most places use the same job estimating resources so it really just comes down to their labor rate. I think the book calls for 8 hours to do our clutches.
 
If you have done other clutches, it should not be a problem.
If it is your first one...
Leave extra time to get your flywheel surfaced, and make durn sure you don't brake the plastic slave cylinder.
I did my first one at a local shop, and it took days to get bolts ordered that were bad and the resurface job. The next time, I went to Dave Mitchell's shop and let the Pro's do it. 1 day, (7hrs)had everything we needed to fix any surprises and also R&R my 5spd at the same time.
He is about 5 hours for you.
Gene

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CPFF's Dowell Pin Jig Available in GLTDR Region! 1997 Cummins Dodge 4x4 "One Piece At A Time" Bombed & Amsoiled. Amsoil Executive Direct Jobber, Member of: NRA Business Alliance, GLTDR, WANTED: Wrecked Dodges.
www.awdist.com
 
I just changed mine out last week in the driveway... and it was my first. I wouldn't do another one without a porta power. I wish I had known that before I started it though. Where was this thread a week ago? lol. Anyhow, just to reinforce the comments above... get a porta power (for the crossmember) and allow time for the flywheel resurfacing. If you have any questions, I'd be more than happy to assist. Good luck.

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98. 5 2500, 24v, 5 speed, QC, 4x4, 4. 10 LSD, short bed, Line-X liner, tow package, camper suspension, Westin nerfs, camper shell, TST PowerMax Competition, 275 RVs, Psychotty air, HX-40, 4" straight pipe exhaust, Southbend clutch, ProComp A/T 305/70/R16s, EGT/Boost/Fuel pressure pillar gauges, Grover air horns... Love my Cummins, no love for Dodge
 
Thanks for all the help. I have the transmission jack and a big place to do it, along with a bunch of guys to help out. I was going to order the flywheel all ready resurfaced from Southbend, just so i could get it done in a weekend, and not worry about it. I have rebuilt motors, and changed trannys, but i have never messed with the clutch, most were autos. I think i will be taking this project on myself at some point this summer. my question now is about this frame spreader. A 20 ton bottle jack and a piece of steel wouldnt work? How far will i need to move it? Thanks for all the great help. well worth the 35$ per year.

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(Silver Bullet)1999 Ext Cab 4X4 5SPD, All options. Power Max 3(adjustable), K&N Filter, no muffler, Pyro,Fender Flares, Toolbox, bedrail covers, 450 watt Kenwood Sub, 33 12. 50 16. 5's, 3. 54's... Soon to have: 4inch, DDIII's, Southbend clutch.
 
The bottle jack will work but the issue is stability and safety. I took my crossmember out with a bottle jack and I wasn't too happy about it. Look at it this way... for the money you're saving on the install you can easily buy a porta power set and you'll be a lot safer in the process. No sense getting hurt. You might want to check this out too.
https://www.turbodieselregister.com/ubb//Forum17/HTML/002358.html

[This message has been edited by Vaman (edited 05-29-2001). ]
 
Mike,
Like everyone else has said, it is not a difficult job, just time consuming. With a transmission jack, clutch alignment tool, and enough friends around, it should take you no longer than an afternoon.

We put a SouthBend clutch in Dougs truck this past Saturday in about 6 hours start to stop.
I have a porta-power that we used to spread the frame to remove the cross member. If you want to borrow it sometime, just let me know.

We would be more than happy to help you out with the install also.



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Andy@Advanced Diesel Technology
 
Some, I repeat, some trucks do not need to bespread. Go up and back with the cross member, it will fall out. Mine worked that way, it is a 97. I learned this the second time around, the spreading deal scared the hell out of me!
Gene
 
Andy, I just emailed you!


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(Silver Bullet)1999 Ext Cab 4X4 5SPD, All options. Power Max 3(adjustable), K&N Filter, no muffler, Pyro,Fender Flares, Toolbox, bedrail covers, 450 watt Kenwood Sub, 33 12. 50 16. 5's, 3. 54's... Soon to have: 4inch, DDIII's, Southbend clutch.
 
Good thing it's a 5-speed, they are pretty light compared to the 6. The 6 is about 350 lbs, and that is without a t-case!

Getting the crossmember out is not bad if you don't have a frame spreader. Load up the friction surfaces with WD40, and BE SURE there is no undercoating on there! That acts like glue, and you can count on a battle. I have done dozens of trans R&R's, and sometimes the frame spreader won't fit, so I have to do it with a mallet an an imagination.

Save yourself the trouble, and get a frame spreader.

I gotta get a clutch... Bad... #ad


Where's Peter? HEHEH
 
I work In a transmission shop and have installed a couple centerforces on 12 valvers... I do this all the time, so with a lift, transmission jack, no porta power and air tools, I can get one in and out in 3-1/2- 4 hrs. If you do decide to do it yerself, here's some tips from experience.
I'll give ya my order of operation first, then I'll ramble about do's and don'ts. 1. take shifter out from inside cab. 2. drain tcase. 3. push somewhere else if ya spill some and are working on yer back. lol 4. take rear driveshaft out. 5. Drop crossmember 6. remove front driveshaft and tcase 7. undo all wires, slave cylinder from transmission 8. With an impact and long extension, undo bellhousing bolts. 9. pull back and set her on the ground... 10 install clutch/flywheel ect. and go back in.
I personally wouldn't use a portapower unless I just had one laying around. I worked at the local Dodge dealership for about 6 months and see a dodge at least once a week now, and all the late model pickups have the same crossmember design. And I have never had to use one. It wasn't easy the first time I did one though, but A master tech handed me a big dammit hammer (biggest deadblow hammer you can find) and with a maximum of 10 blows, 5 on each side, from the front edge going back and up, the crossmember should be on the ground. (be sure to jack up on transmission till it hits floorboard first, so mount bolts are not in yer way. Going back in is tricky the first time, too. the sides of the crossmember are slanted out. To go back in, hold the crossmember at the bottom of the frame, and rock it back so the narrow part of the crossmember gets knocked in first. drive it in and it will act as a wedge. when it gets half way in, rotate it into the proper position for install. Again, the whole procedure takes max 10 blows from a persuader(dammit hammer) if ya do it right. I use (I believe) 18mm deep socket w' 4" extension on 3/8" impact to get the nuts through the holes in the frame and a 15mm wrench on the inside holding the bolts. Might wanna have a magnet on a stick handy the first time, 'cause you'll probably drop the nuts inside the frame. also, drain and remove the transfer case. It has (I believe) 6 15mm bolts or nuts holding it to the transmission. Gear wrenches come in handy but are not necessary. I usually support the transmission with a jack, remove rear driveshaft and crossmember, then lower the jack until the transmission stops coming down to make getting front drivehaft and transfer case bolts easier to get to. You can take transmission/tcase out as a single unit(I've done it both ways), but the extra hundred pounds of off balance weight makes it **** near impossible to get the pilot shaft lined up with the bearing going back in. You might also need a shorty 15mm wrench to get the top tcase bolt. I don't think ya do on the Rams, but I do a lot of jeeps too and you need one for them. Other than that, I would definitely use a transmission jack and a ratchet strap unless ya really want a hernia. especially strap the tcase to the jack, because they are not fun to catch mid air. ( I don't know if I want to admit to having done that before either. )I know this is long and out of order, but the time/effort/money you save will be your own. also, take the tcase fill plug out and sit it on your seat or someplace obvious, because it's real easy to forget to refill w/ transmission fluid. ( almost did that one time) I hope this helps. Email me at Rod77zilla@aol.com if ya have any trouble and need quick answers. good luck!
 
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