Hello fellows,

Got a serious problem I need help with. I have a 99 CTD 3/4 ton with a five speed. I bought this truck new and it has always had a vibration at 38 miles per hour that Dodge coundn't fix so I finally gave up on them. About a year ago I had to replace the clutch. Tho old clutch disc came out in several pieces and the pilot bearing was worn completely out. It was about as thick as a piece of paper when I took it out. I replaced everything and the thing was real jerky when starting off in second gear, even if I was starting off going down hill. I took it back out and replaced it with a kit from a well respected clutch and brake place in Dothan, Alabama. This one was better but the jerking when taking off was still there but not as bad so I started in first gear only. Now, not even a year later I started getting an unbelieveable noise when I would start to push the stick to mesh it in gear, just touching the stick with the slightest resistance would cause the noise. I took the tranny back out today and the piolt bearing is about half worn through. The difference between the size of the tranny pilot shaft (that goes in to the pilot bearing) and the inside diameter of the pilot bearing which is still in the flywheel is 76,000th of an inch, which must be what caused all the noise. The noise wouldn't show up until I had driven a few miles each time it was cold, like overnight but then it would happen again when I would start to put it in gear from a stop. I thought the tranny was going to fly apart, thats how bad it was. The pilot bearing is the bronze type that came with the clutch kit. What is wrong here? What caused this? This truck has never been abused since it was new.

 

You may have too much play in the input shaft, or warped bell housing. I could be wrong. For a good pilot bearing, call SBC and get a roller bearing.

 

I agree. A 99 should have a roller style bearing.

If a bronze bushing was used, it should've been soaked in oil overnight.

Make sure the pilot surface on the input shaft is not scored or damaged, or the next bearing won't last long either.

Hope this helps.

 

I appreciate the advice guys, Can you give me a way to contact the place you mentioned and I'll get it coming my way? Do you think there has been a problem with the truck since it was new causing these repeated problems? This truck has been driven pretty much the same way a grandpa would operate his family car.

Thanks again,

Sonny Heath

 

I agree that a roller type bearing is best in nearly all cases, including our trucks. However I always thought that the "bronze" type bearing were actually Phosphor Bronze and they were self lubricating and NO lubricant at all should be applied to the bushing or the shaft as it clogs the surface of the bushing and causes binding.

 

They are talking about south bend clutch. Google them and give em a call.

 

Also, you need to make sure your input shaft portion that engages the pilot brg. is not undersized, as well as VERIFYING that the bellhousing is placing the transmission concentric with the crank.

I was kind of surprised to see the FSM cover the procedure to check it, given the level of precision that parts are made today.

You need to dial indicate both the locating bore for concentricity and the mounting face for parallelism.

 

That's the first I've heard of that. I was always taught that being porous, they would absorb oil, and to soak them. It has always worked well for me. I'll have to check into it.

 

I know this isnt your problem because it alone couldn't cause your trouble, but you never mentioned (or I missed it) your flywheel status. Did you get it resurfaced?

 

Like Bark said, is the flywheel ok? Not warped, burned. Also, I imagine, "never had one of these apart" there should be dowel pins between engine and bell housing. Are they missing or damaged? This could cause chatter and pilot bearing failure. Also look for anything that would prevent the engine and bell housing mating together perfectly flat.
Ted

 

About a flat teaspoon of high temp grease is called for in bushing bore. Lack of lube causes squealing, Hard shifting, and failue. Check and make sure alignment dowels are present.