Clutch replacement pointers
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Senior User
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Clutch replacement pointers
Clutch in my IDI finally gave up the ghost sitting in traffic on my way to class, started smelling clutch and then the pedal got spongy as hell so I limped it home.
So I've ordered the upgraded SBC singlemass conversion kit
Should be here this week which means I will replace it this weekend.
I climbed under my truck today just to see what I was in for. Doesn't seem to bad. Oddly enough I couldn't see the bellhousing bolts, where are they located exactly? Do I need to drop the exhaust?
From what I understand/see it looks like I just drop the rear cross member, undo the shift linkage from up top, bell housing bolts and voila, it's off?
Thanks!
So I've ordered the upgraded SBC singlemass conversion kit
Should be here this week which means I will replace it this weekend.
I climbed under my truck today just to see what I was in for. Doesn't seem to bad. Oddly enough I couldn't see the bellhousing bolts, where are they located exactly? Do I need to drop the exhaust?
From what I understand/see it looks like I just drop the rear cross member, undo the shift linkage from up top, bell housing bolts and voila, it's off?
Thanks!
Logistics Pro
Joined: Apr 2005
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Are you sure the clutch is bad and not the hydraulics?
Pull the carpet, remove the transmission cover. Remove the shifter, have small spring fall into transmission, drain transmission, remove PTO cover to remove small spring.
Pull drive shaft and rear cross member.
Remove dust cover/flywheel inspection cover.
Disconnect wires from B/U switch.
Pull transmission, turkey's heavy so be careful.
Don't remember about the exhaust.
Drink beer. (For safety's sake this step is last.)
Pull the carpet, remove the transmission cover. Remove the shifter, have small spring fall into transmission, drain transmission, remove PTO cover to remove small spring.
Pull drive shaft and rear cross member.
Remove dust cover/flywheel inspection cover.
Disconnect wires from B/U switch.
Pull transmission, turkey's heavy so be careful.
Don't remember about the exhaust.
Drink beer. (For safety's sake this step is last.)
Elder User
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Not sure on a 93 model but on my 86 i didn't have to pull the exhaust or starter. you should be able to get to the bellhousing bolts fairly easy. chevy is riht the turkey is indeed heavy. i hope yours is 2wd, helps when you don't gotta take out the tcase too.
I can't really say i have many tips to give after doing mine. It was just trial and error and trial and error and trial and error.
If you are using a jack to lift it, make sure yours does not have a hydraulic leak like the one we used to install mine (:
Makes it tough to lift it into the air while balancing the trans on the jack and trying to line it up with the t/o bearing hole not to mention the floor board bottoms out on the top of the trans before you can level the trans out.
One thing i did learn, i can not operate a jack with my leg...
Good luck buddy.
Its simple, just getting it done si the hard part.
I can't really say i have many tips to give after doing mine. It was just trial and error and trial and error and trial and error.
If you are using a jack to lift it, make sure yours does not have a hydraulic leak like the one we used to install mine (:
Makes it tough to lift it into the air while balancing the trans on the jack and trying to line it up with the t/o bearing hole not to mention the floor board bottoms out on the top of the trans before you can level the trans out.
One thing i did learn, i can not operate a jack with my leg...
Good luck buddy.
Its simple, just getting it done si the hard part.
Logistics Pro
Joined: Apr 2005
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Okay, that sounds like a clutch alright.
Eric, did you change your clutch with your bell housing installed? Sounds like it if you didn't pull the starter. In any case that's not an option in this case as the ZF5 has an integral bell, it's coming off.
Eric, did you change your clutch with your bell housing installed? Sounds like it if you didn't pull the starter. In any case that's not an option in this case as the ZF5 has an integral bell, it's coming off.
Logistics Pro
Joined: Sep 2007
Posts: 3,737
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From: Western Mass
Yes the ZF5 has an integral bell, so it comes off as part of the transmission. However, the starter bolts to the spacer plate that is bolted to the engine, and NOT the transmission. So there is no need to remove the starter.
To get to the top two bellhousing bolts it helps to have a really long extension. I think what I've done is the socket, u-joint, 24" extension then ratchet. Maybe another extension in there? I want to say the bolts take a 3/4" socket, but I might be wrong.
It also helps to make up 2 special bolts to help line things up. Basically just take the same size bolt, cut the head off, and cut a slot in the end for a screwdriver. I put these in the middle hole on either side. Makes it a lot easier to line things up and get the bolts in place (or hold it up taking the last two out.)
Logistics Pro
Joined: Apr 2005
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Okay, sorry, I stand corrected. Forgot about the spacer and saw the cone recess in the bell on my ZF and figured it was standard.
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From: Morgantown, WV
how much that set you back? I think the clutch in my truck is going bad. I've heard of the conversions but haven't really seen too much on what they actually are, anyone shed some light? sorry to hi jack, haha
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It was pricey. Retail is about 700$.
The dual mass fly wheel is a two piece design that was aimed at keeping vibrations down. As they age, the two parts tend to separate and cause vibrations or noises. In extreme cases, the outside piece separates literally cuts through the bell housing
You can replace the DMF which is pricey or you can upgrade to a simpler, arguably more reliable single mass (SMF) kit.
This includes a new flywheel and clutch kit. The single mass is a one piece design which has no parts to wear out like a DMF.
I sell them all day long for VW TDIs.
The dual mass fly wheel is a two piece design that was aimed at keeping vibrations down. As they age, the two parts tend to separate and cause vibrations or noises. In extreme cases, the outside piece separates literally cuts through the bell housing
You can replace the DMF which is pricey or you can upgrade to a simpler, arguably more reliable single mass (SMF) kit.
This includes a new flywheel and clutch kit. The single mass is a one piece design which has no parts to wear out like a DMF.
I sell them all day long for VW TDIs.
