clutch replacement refresher

[Tuvlo]

I have not changed a clutch in some time and i have never changed one on a 4x4, so if some of you guys could give me a refresher course. I guess i need a simple step by step for our trucks.

[wedgemon]

Been there, done that...

Here something I posted on another board about a year ago.

12/23/04
1980 SM465/350ci Clutch Lever Help!

OK, for a month or so the Throw out bearing has been
buzzing - once in awhile. Figured I could wait till it
warms up to fix it. Well, last Friday, I got 2 shifts out
of it at lunch and It sounded like the Wheel of fortune -
rapid fire clicks. and no clutch response - stays in
gear. So, I read up and it looks like it may just need to
hook my dangling clutch lever/arm back up to the T/O
bearing and pivot ball.

Stories over. Now the questions.

1) Can this be done without dropping the trans? Just
shove in around the T/O and re clip it to the pivot?
2) Anything else to look for?
3) Can this be done on a weekend with 1 pot of coffee,
6 Dos Equis Cervezas, and "Salty Sam the Sailors
Bawdy Language Guide"? Or do I sell the kids to the
gypsies for professional drivetrain help?


ONE WEEK LATER...
OK! I've dropped everything, Replaced Pressure plate,
clutch disk, flywheel, pilot and T/O Bearing. Bought a
tranny Jack. Have the engine supported and levelled and
trans is aligned. Alignment tool is removed.

Why the heck can't I get the danged thing to go
together?? Yes, I have re-checked the clutch alignment
and I triple checked the pilot on the end of the shaft
before installing it. I've spent over six hours under the
truck trying to fit it!

I'm open to suggestions. Maybe alignment studs in the
mounting holes??

Any advice or help would be greatly appreciated. I'm
missing out on Reno's heaviest snow since 1917!!!!

Thanks!! - Dave
ps: I've got $50 and a six pack for anyone in Northern
Nevada wants to come by and make this work!!


Our stories are similar.

Round up some big friends. Put the truck on stands, high as is safe, all four corners. Get a trans jack. Remove the trans hump cowl and shifters. Pull out from below. I used an A-Frame and come-a-long from in the cab to help lower it. This SM465/NP205 combo is HEAVY!!

As you read above, the re-install alignment of the pilot shaft into the bushing is the tricky part.

Tricks:
· Inspect the flywheel. Looks funny at all - spider
cracks, hairlines, too shiny. Take it off and have it
surfaced.
· Change the trans and case oil while it’s out.
· GET A NEW LEVER BOOT! Keeps the junk out that eats the
T/O bearings.
· Get a new lever, too. And an adjustable pivot ball.
· Remember to lube the Z-Bar.
· Think about a new trans mount on the cross member.

The rest is easy. The weight and awkwardness is torture.

If you have any other questions let me know.

- Dave