Sorry for the long delay in updates.
Been way too busy.
Finally got to working on the truck this last weekend.

I replaced the slave cylinder with a smaller bore cylinder from SBC.

I flushed the fluid before putting it together, and during the bleeding process(Plunging the actuator shaft manually), I continued to get lots and lots of black fluid coming up into the reservoir from the master cylinder.
It was SOOO much black fluid, that I felt compelled to suck out the reservoir and replace it with clean fluid. I repeated this process at least 10 times before I was satisfied I had enough of the contaminated fluid out. (I have never seen this much contamination of any automotive hudraulic clutch or brake system in my 25 or so years of messing with these things).

NOW, i finally have plenty of travel on the clutch. This fixed most all of the problems I had with the hard shifting. It still drags, and seems to have plenty of inertia, but it is 10x easier to drive than it was before. I think it is working as well as any dual disk would.

Root cause of the problem was most likely this extreme contamination. Its not surprising to see lots of organics growing in Dot3 that hasnt been changed in like a decade, but this clutch is only about 2 years old. Kind of bizzare actually. I am not sure what the hell happened. This clutch kit came from SBC with an all new hydraulic system, pre bled.... maybe it sat on the shelf for a while?

 

Cannot comment on the SBC
But I added the Trans Cool on my G56 and then put 8 quarts of Delvac 50 in and a huge irovement in shifting and noise. I live in Sandy Utah. Nights are getting down into the high. 20's and a little stiff for 50 feet but then better then ever.

 

I just noticed this but I was having the same problems and the little spacer under the throw out pivot ball wasn't removed and when removed it cured the problem

 

I removed it.

 

Finally got the Delvac 50 in the tranny last night.
8 quarts with the fast coolers installed under the PTO covers. This didnt really make much change. Noise is improved a bit, shifting is a wee bit better but not much.

The shifting is a lot better than it was before i started(Bleeding the clutch hydraulics is what primarily fixed it), but still kinda blows.

Its fine for the highway, or mountain/country roads.

But, I end up spending a lot of time in stop/go traffic, and through urban streets with constant stoplights. It really sucks for this. When pulling into 2nd from a dead stop, I have to depress the clutch and wait 5 seconds before pulling into gear. Then the rest of the sifts need to be done with the wheel/engine speed matched.

 

I can say that the Amsoil 75-90 MTG is a substantial improvement over my Delvac 50/Amsoil 5-30 synchromesh combo. Straight Delvac 50 would be too thick IMO despite Mercedes recommendations.
My friend just returned from Texas and found his SBC 3250 DD pretty stubborn until warmed up. He's got the NV5600 and stock Mopar fluid which is pretty thin.
I've driven the same truck in mild San Diego conditions and felt it shifted fine.

 

I was running that Amsoil 75-90 synthetic before as well.
None of the 3 oils really help me get the syncros to work well with the dual disk clutch.

 

Well,if you don't tow heavy an SBC OKHD might work for you.
I can't make it slip in 5th with Smarty sw#7.

 

Still running my $500 LuK DMF clutch kit, still running the Edge chip. Running the stock ATF+4 from Mopar for fluid.

I have not slipped this clutch once, and there is no transmission noise what-so-ever. No hard shifting either, even when temps up here in MN are well below zero.

If you are going to eliminate your dual disk and want smooth shifting and no noise- consider LuK's DMF kit that is good to 850 torque. It's half the cost of the SBC, and none of the noise.

 

I wonder how it would hold up to Smarty. My friend's Edge doesn't fuel as low as Smarty.
Prior to this SBC I had a Valeo smf conversion with 800 # torque and it slipped with Smarty #5,285's and my camper,same as what I have now.
I do miss the silent trans,but Amsoil MTG shifts nice and minimizes noise.

 

07 5.9 6 speed man sbc and cant put it in gear,72,000 miles on truck with maybe 6,000 on clutch,meeting with the shop that installed it dont want to get in the middle,but love the help on here!! So Diesel Junkie the spacer removed fixed it?

 

If I ever need this clutch replaced,I'll have the shop supply it. That way I won't be caught in the middle.

 

I have the same issues with my OFEK on a G 56 transmission. On a G 56 transmission some days it is so easy to shift, that a three-year-old child could do it. Other days it is so stiff to put in gear it is almost unbearable. R 1 and 2 are the problem gears. Randy at SBC wants me to check free play on the pivot first by measuring the extreme forward point of the pivot and extreme rearward point which the play should be 1/2 to 5/8". I believe the issues are 1) the input spline has rust or dirt on it which causes the disc to not float into the gap between flywheel and PP or 2) the SBC disc has a harder spline centre than the stocker and it has worn a groove into the shaft and prevents the disc from floating. Evidence of 2 is the previous poster who installed a smaller bore slave to get more travel and the issue basically still exists.

 

Thanks for info,I'm going back to the shop that installed it to help me,let you know what we find.

 

I went through everything, and I would have to say the biggest contributor to my problems was the hydraulic fluid. It must have absorbed a lot of water for some reason(At only about a year old too).... got a LOT of dark fluid out of it. It was not easy to purge either.

All in all, not perfect, but the system is working fine now.

After adding the fast coolers and 8 quarts of Delvac 50, my complaints need to be tempered. Still no bueno for stop and go traffic, but totally fine for road trips.