Engine/Transmission (1994 - 1998) new clutch mass casualty

[NBowlin]

i installed a new dd into my truck today.

when i put the new/bigger input shaft in and tightened down the carrier it bound up the transmission. you couldnt freely turn the input shaft with it nuetral. it was bound up enough that it would turn the output shaft. now i figured it was cause the bearings were new or something stupid like that. so we put it all back together figuing the motor would overcome what my hands couldnt. well apparently it was pretty serious about not wanting to turn. its bound up enough to where it pulled down the idle in my truck and made some bad sounds.



what would swapping the input shaft out for the 1 3/8 shaft do to bind things up inside? is it spose to come with a spacer or something? any ideas?

 

[NBowlin]

well went back at it today.



pulled it all back out to address the transmission binding issue. resolved that by making a pair of shims for the input shaft carrier housing. transmission free spools in nuetral like its spose to. good deal... ... put it all back in there. no more squeeling noise, its not trying to walk away from me, so i push in the clutch to put it in gear. . cant even force it in gear.



pull it all back out again, then start looking at the slave cylinder and the fulcrum for the shift/release fork. cause in the instructions it said to pull the washer from under the pivot ball. so we put that back in there, put it all back together, same story.



then we thought maybe the slave cylinder didnt have the throw to get it done, so we built an extension for it and no good on that either.



now someone here has had to of had a simular problem at some point. i am looking for any ideas or suggestions. thanks

 

[SMorneau]

I know a guy who put dd clutch in a 5 speed truck and he could not get it into gear either. So he put it in gear and then started the engine and beat the hell out of the clutch for awhile and then it started working.



My truck did the same thing and after driving it about a week it started to cooperate. Now it works fine if you allow it about a second or so to drop into gear.

 

[csevers]

When you swap an input shaft in a 5 speed you have to watch out that you have the front main shaft bearing in place and the bancake needle bearing in also and the shaft needs to slip in to the front syncro, if you look at the input shaft it has spine on the trans side of the bearing that have to line up. It is possible to just put the shaft in and not have the input shaft slide in to the front syncro, this would give you a great problem when tighting the front cover. If you look at the counter shaft gear and the input shaft gear they should line up perfect NOT off by a 1/4 inch. You should never have to shim the front input shaft cover.



What Dual disc did you install?? Some of the dual discs you have to modify the release fork to make more clearence for the extra height of the overal clutch assembly.



Any more info would help.



Craig

 

[Fred Swanson]

A weak slave/master will cause not enough travel to fully disengage the clutch. The DD clutches are harder to engage a gear at first, but they do get easier.

I've got about 10K on mine now, and it works much better than when new.

 

[NBowlin]

the shims on the input shaft cover are only a few thou thick. it is very close, but i think its in the large bearing, and it cant be pressed on anymore. it is in the synchro and the small flat bearing is in there as well.



this one did require mods to the shift fork to clear the input shaft carrier. it was done in accourdance to the instructions.



no to the starting it in gear and using it. it walks when you start it in gear. and you can not make it go into a gear once started with the clutch all the way in or not.



we have eliminated in our minds down to my slave or master cylinder basically not haveing enough power to move it. everything is installed correctly. the gear box when not running or out shifts thru the gears fine. the pedal feels like it always has. its a mystery.



the pilot bearing isnt the problem either. all is well up there.



i am looking forward to calling the people and seeing what they have to say. please keep it coming though