installing clutch tomorrow, what to look out for

[bigtruck81]

my 80 GMC needs a new clutch. went today and picked up a custom clutch kit (kevlar disc, pressure plate, throwout bearing, pilot bearing, and a new fork) and had my spare flywheel turned. i'm planning on pulling it apart tomorrow night and finishing over the weekend. the truck has a 465 and a 205 in it. is there anything i should look for when i separate my trans and transfer case? im planning on changing the fluids while im under there, what fluids do each take? and how much? any general tips that may help in completing this job?

[Burt4x4]

I did that once, it was back in the 90s..so hear is what I remember:
I droped out the 465/205 combo without seporating them..no I mean I litterally droped it, ok it fell off the tranny jack I was using. Getting it out was the easy part. The reason it fell was as soon as I seporated the tranny and engine the weight from the 205 rotated both and it rolled off the jack.

Both take 90W gear oil, I think two gal. should doit but I can't remember...
I cleaned and painted the 465/205 also.
Setup the flywheel/clutch assy to the engine, use the alignment tool when you tighten up the pressure plate. Just go slow and make sure all the surfaces are clean, I also bought a new clutchfork Boot from GM, it was like 12bucks. worth it to keep dirt out of your clutch assy.

When you are ready to put the 465 back on take two bolts that fit into your bell housing, cut the heads off, screw one bolt into the top right of the bell and the other top left. Thease headless bolts will act as guide pins so you can slide the tranny back into the engine. Once you have the tranny lined up correctly it will slide right in....if it is not sliding in you are not lined up, wiggle shake rattle swear alot drink beer...ummm ya that is about it
Good luck
Burt

[OLDCHEV4X4]

Check the gear oil level in the TC. If its over full, I would replace the seals in the trans to TC adapter. And inspect the adapter sleeve for excess wear.

[MightyFine69]

Try to get everything as straight and level as you can before you slide the trans/case combo forward. If you don't, you will play heck getting it to go in. You may also mess up your new pilot bearing. Also, make sure to use the alignment tool when you bolt up the pressure plate and disk. It makes things much easier. This is all pretty much common sense, but it never hurts to mention it.

[wedgemon]

How'd the re-install go?? Inquiring minds want to know....!

- Dave

[bigtruck81]

still toying with it. ended up not being "bad" clutch at all, but a busted input bearing retainer. the surface that the throwout bearing rides on was completely broken off, and the throwout bearing was extremely worn. not a bad idea to replace the clutch while i was in there anyways, especially with it being a better quality clutch, not to mention i went from a 3 finger clutch to a diaphragm clutch. havent driven the truck yes, as i still have to adjust it, put fluid in the diffs, and grease the new u joints i put in the rear. i'll probably know later tonight if i can get it to adjust out.

[bigtruck81]

WOW is all i can say. it adjusted out just fine, and grabs great.

i did run into a bit of a snag though. upon taking the shifter off, i discovered cracked spot welds, so i welded it up as per http://www.pirate4x4.com/tech/billav...465/index.html

if you weld your shifter, make sure that you dont completely fill the space just below the ball. i did, and ran into a situation where i had 2nd, 4th, and reverse, but no 1st or 3rd. a little grinding and several trial fits later, i am back in business. going to drive it to work tomorrow, and maybe tomorrow night put it to work.

[wedgemon]

Big - That must be a record for a 465 install!! Danged things never line up in less than 2 weeks.

Good Job!

- Dave

[Hoods69BadBowTie]

Yeah I was going to say that was quick. Glad to hear that everything worked out good on it.

[bigtruck81]

would've been back in Saturday night if i had known that i needed to get an input bearing retainer. its not really all that hard to do with the right tools. i've got a tranny jack here, and borrowed a transfer case adapter for a floor jack.

*edit* not sure why it says it was posted on 3/1 when it was actually posted on 2/29.