Clutch install
Clutch install
My clutch has just about had it, and I plan on replacing it with a South Bend unit... but I'm not looking forward to the install. Whats the best way to support the tranny as I remove it? I'm more at home working on autos and I usually use a floor jack and a 2x4 under the pan, but there doesn't appear to be any good place to do something similar on the NV5600. I don't own a tranny jack nor do I have easy access to one. I got plenty of friends I can bribe with beer but I understand the 5600 is really heavy, plus I got the transfer case to contend with also. Anyone got any tips/advice, or maybe a how-to article? Your help is, as always, appreciated.<br>Dave
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Re:Clutch install
Can't say about the 5600, but R&R on my 4500 was a major PITA. I borrowed a trans jack - and DARN glad I did. It would be really tough to do it otherwise. The 4500 weighed ~250 w/o the transfer case (which I'd yanked so many times I could almost do it blindfolded). Think the 5600 weighs ~350 lb alone, so wouldn't even attempt it w/o a decent tranny jack. You will need a jack that has fore/aft & L/R adjustments, else you will never get the tranny back in, IMHO. The trans & engine are installed in the frame at the factory as a unit. The body is dropped onto the frame. ABSOLUTELY ZERO thought was given to facilitating later replacement. Trying to get the tranny to go back in, line up the clutch/splines, and fit the shift tower back through the floor took longer than rebuilding my tranmission (literally!). There is no room to work, and a really tight fit around the shift tower. You will also need to support the engine as well, and raise/lower it as r'qrd to mate back to the transm. Would be easier on a high-lift I presume, but I did it in my garage the hard way. Also, you will need to jack the truck up several inches min in order to clear the trans from under the truck (on the jack). Mine wouldn't come out while on the jack (too tall for frame rails), so just manhandled it off the jack - which would be even harder w/the 5600. Don't know what the 241 cases weigh now, but used to be ~ 80 lbs - so add that to the 5600 if you try to R&R as a unit. Resintalling was an exercise in patience, perserverance, and pain (mostly). Never could get the trans to go back in exactly right, and the jack was too cumbersome for maneuvering, so finally crawled under the thing, and just benchpressed the POS back in. Keep in mind, if the input splines don't line up with the clutch, you will have to keep pulling the trans out to turn the shaft slightly, or as I did, stick in 4th (direct,on 4500), and turn the output shaft w/one hand while pushing the trans forward, until the splines line up and go in. DO NOT tighten bolts in bellhousing until splines align fully, or something will break. Sorry, can't give more details on the 5600, as I have only done the 4500. BTW - the flywheel bolts are ONE TIME USE/stretch-to-yield types, according to Cummins/Dodge. May want to acquire them before your R&R, as they are metric, short, grade 12.9 (4500 anyway). Had to order mine from Cummins/Indiana. Pick up a clutch alignment dowel/tool if you haven't already. Be sure to clean crank hub before installing flywheel (photo attached), or you'll have runout problems, if dirty.
Things may be different on the 5600, so maybe someone else has more info.
Just my .02...
Good luck!
-Scott
Things may be different on the 5600, so maybe someone else has more info.
Just my .02...
Good luck!
-Scott
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Joined: Aug 2002
Posts: 3,308
Likes: 1
From: Kerrville eastern new mexico, west texas
Re:Clutch install
It took me about a day to put mine in on my 01. Definetly get a jack. I did mine by myself. Dont forget to replace the pilot bearing and becareful with the input shaft and dont hurt the bearing. If you have some friends to help you its not that bad. it is a tight fit under there tho. good luck
Re:Clutch install
Before you install the clutch disc in the pressure plate, slide it on the input shaft on the trans. Someone in another thread had a hard time getting their input shaft in because there was a burr on the clutch disc which wouldn't let the trans fully seat. As for the trans jack, It would be much safer and easier with one.<br>Good luck
Re:Clutch install
It was me with the clutch disk burr, that little piece of metal cost me a full night without my truck >
I would go with everyone else and say to get a good jack, the job will go much smoother. Another thing I've done is had a buddy in the rear of the truck use the rear drive shaft as a lever against the rear-most crossmember. Not sure how correct this method is but for those small final adjustments when your arms are burning from being over your head it seems to help. good luck with the install......andy
I would go with everyone else and say to get a good jack, the job will go much smoother. Another thing I've done is had a buddy in the rear of the truck use the rear drive shaft as a lever against the rear-most crossmember. Not sure how correct this method is but for those small final adjustments when your arms are burning from being over your head it seems to help. good luck with the install......andy
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Re:Clutch install
NV 5600 is heavy. About 200 lbs more than NV 4500.<br>With the S/B clutch, you'll have to resurface the flywheel. Install new pilot bearing. Examine input shaft for any burrs, galling etc. Don't reuse a questionable input shaft as it'll take out the new pilot bearing.<br>I like to remove the transfer case, then the transmission.<br>The crossmember is a tight fit. Some trucks are more troublesome than others. Anyone else experienced crossmember removal trouble?<br>A transmission jack is a must. A floor jack with the transmission adapter will work but it should have a safety chain and be rated for the weight.<br>Like everything else in life, the first one is the hardest.<br>John<br>
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