Attention: TDR Forum Junkies 
With the help of a couple of friends we installed a new South Bend Con OFE clutch in my 06 last weekend. Thanks to all of you who offered pointers about the installation. It turned out to be a bit more of a challenge than I had anticipated due to a malfunctioning transmission jack. The jack was as high as it would go and
would not stay extended. Every time we would get it lined up it would bleed down. Finally brute force and a couple of strategically placed floor jacks did the job. I did learn a few things that I will pass on to those contemplating a clutch install. Some of these things I learned the hard way and some was
good advice from fellow TDR members.
1. Get some help. I personally could not have done this alone.
2. Get a good jack with sufficient height.
3. Alignment is everything when installing the transmission. If it is not perfectly centered in the clutch splines , it will not go in no matter how hard you push. Once we got it lined up it popped in the last inch with very little effort. I did not hook up the clutch and push it in as suggested, once lined up it went right in. this was the biggest hang up, if it is lined up it will go right in. If it won’t go in the last couple of inches it is simply not lined up correctly.
4. This may be common knowledge, but in order to undo the transfer case drive line you need to jack up the left front tire so you can turn it and get the bolts out.
5. Jack the truck up at least 8 inches. Sure was nice to have the room to work under it. You will need to get the tires up at least 16 inches if for some reason you want to bring the transmission out from under the truck. There is no need to though.
6. There are two wires hooked to the transmission on top you need to unhook them before you can slide it back enough to get to the clutch and pressure plate
7. Be sure to put the transfer case back in gear before you try the clutch out. There was a moment of panic the first time I started it after the installation, put it in gear let the clutch out and nothing happened.
8. If the truck won’t start after install you need to lengthen the adjustment rod to get the start safety switch to work.
9. I left the transfer case on. I personally feel you could go either way. It would definitely have been easier with the transfer case off though.
I like the new clutch. It is different than the factory clutch in a few ways. It tends to be a little grabby. Not bad, but you will notice it. The other thing you will notice is it tends to growl at idle when in neutral or idling around at low power. It doesn’t do it all the time though. The truck is now a bit noisier. I talked to the fine folks at South Bend Clutch and they said all of those items are normal for the Con OFE. One last note, the folks at South Bend, Peter and Woody are excellent people to work with. They patiently answered all of my questions explained in detail why the truck sounded different and acted a little different. They never once said “ that’s just the way these clutches are. They wanted me to understand why and I appreciated that. Now back to my Smarty.
Jeff
