Any and all help or clues is appreciated. A little back ground on the truck, 2WD 2007 crew cab flat bed 6.7 6 speed. The truck is a customer of ours it is a fleet truck for his landscaping company but pulls very light loads 7500 max. At 29,000 miles the truck was hard to shift went to Dodge and had a new OEM style dual mass clutch installed under warranty. At 50000 miles it was in our shop was very hard to shift or get in gear, a new OEM style LUK clutch like with new OEM style hydraulics were installed. Installed as well were new pressure plate bolts and fly wheel bolts. The truck was great for about 7000 miles at 56800 the clutch had failed to the point where the truck would not move, burnt clutch smell.after investigation it was found the Slave cylinder has failed causing the clutch to slip until failure. At this point we put in an ACE Manufacturing single mass with all new bolts, test drove for 50 miles worked great, gave back to the customer and was back at our shop in 30 more miles today with a smell of burning clutch. today we have checked the hydraulics and have no air in the system, we inspected the firewall for any flexing and it is solid and does not move at all. The trans is going to come out in the AM, Please help with any ideas, things to look for, clues. Thanks Tommy

 

Tommy did you go for road test with the guy? Make sure he's not resting his foot on clutch pedal when driving. You drove 50 miles no problems he drove 30 and clutch smells burnt. I would want to see how he is using the clutch when he drives first. Does he take his foot off clutch between shifts and keeps foot on floor when driving.