hey all, new to the site, looks like i have a bit of reading to do.

here's my story: i picked up a '92 ram 4x4. the previous owner's son was doing a clutch job, and decided to move out and leave the truck behind. so long story short....i got the truck with the trans and t-case in the back of it. a new sachs clutch kit was in the cab. it included the disc, pressure plate, release bearing, and pilot bushing. there was also a freshly cut flywheel in the cab. basically all i have to do is put it together.

I have never done a clutch before.....any tips on doing it, or any tips perticular to the truck?

Is it easier to seperate the bellhousing from the trans and install the bell over the clutch, then installl the trans and bolt it up to the bell; or install the trans/bell as an assembly?

This is going to be kind of a large undertaking for me, i have decent mechanical skill, but i have never done this before

thanks in advance

 

I would put the bellhousing on and then put the trany in place. Makes it easier.

 

And get a clutch alignment tool.
And also check the pilot bushing. (in the back of the crank)

 

i have the alignment tool that came with the new clutch kit. i also have a new pilot bushing to install into the flywheel.

when and where does the thowout bearing get installed?

can someone run through a breif step by step for me?

any other good ideas?

 

Assemble and install parts in logical order as prescribed in just about any service manual. Hints in other posts are fine. Good luck, and not a real difficult job other than getting trans installed.

 

any tricks to getting the trans to line up/spline into the clutch upon final reassembly.

 

Have the trans in gear and turn the output shaft you should be able to feel when the input shaft splines align with the clutch splines. If you do not have a good trans jack I would install the trans 1st then put the transfer case onto the trans it makes it a whole lot easier.

 

Can't stress enough that it's important to have a way to support the trans when reinstalling it. If you're trying to hold that monster up and get it aligned at the same time you'll never get it in. You may be able to rent a trans jack at a local parts store, that would be the best option. Next would be a BIG floor jack on a smooth surface, be sure to strap that dude on there good if you like your teeth. Some guys have used the ole run a pole through the wing windows and use a come-along to hold up the tranny. This works better than you might think, I've used it myself.

Be patient, it will go in but might take a few tries. Some guys have reported that they needed to draw the trans up with the bolts for the last little bit, that's OK if the draw is less than 1/2 or 3/8 of an inch at most, any more and somethings not lined up. If it draws hard, back it out and take a look, better to be sure than trash a 700 dollar clutch.

Like was stated earlier, unless you find a hefty trans jack, put the trans in then put the transfercase on. Together those parts are probably in the 5 - 600 pound range.

Don't forget to overfill the trans with 4.5 - 5 qts. 5W30 synthetic engine oil, and the gear case with 80W90. Check the sticky at the top of the page for more info on how to overfill the trans.