Clutch Installation, Troubleshooting and Support

Below you will find a section on Installation, Troubleshooting and Support, and while it is only here as a general guide many self installers have found this info useful so we have decided to add it to the website.

Downloads:

Do's and Dont's Document - Click HERE
Quick Spec's and break-in procedures - Click HERE
G56 Installation Instuctions - Click HERE
G56 Dual Disc Installation Instructions - Click HERE
Hydraulic Upgrade Instructions - Click HERE

For Technical Support via phone please contact us at 888-682-5247.
For Technical Support via email fill out the form below.

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Installation Information


Transmission & Clutch Removal (NOTE: this is a general guide only ... consult the service manual specific to your make & model for complete instructions)

  1. Disconnect battery negative cable/s.
  2. Shift transmission into Neutral.
  3. Remove shift boot screws from floor pan and slide boot upward on the shift lever.
  4. Remove shift lever extension from shift tower and lever assembly.
  5. Remove shift tower bolts holding tower to isolator plate and transmission shift cover.
  6. Remove shift tower and isolator plate from transmission shift cover.
  7. Raise and support vehicle.
  8. Remove skid plate, if equipped.
  9. Mark drive shaft and axle yokes for installation reference and remove drive shaft/shafts.
  10. Remove exhaust system Y-pipe.
  11. Disconnect speed sensor and backup light switch connectors.
  12. Disconnect transfer case shift linkage at transfer case range lever. (4WD Only)
  13. Remove transfer case shift mechanism from transmission. (4WD Only)
  14. Support engine with safety stand and a wood block.
  15. Remove nuts/bolts attaching transmission to rear mount.
  16. Support and secure transmission with safety chains to a transmission jack.
  17. Remove rear cross member (94 - 02 Dodge trucks require the frame to be spread approx 1").
  18. Remove clutch slave cylinder bolts and move cylinder aside for clearance.
  19. Remove transmission harness wires from clips on transmission shift cover.
  20. Remove transmission to clutch housing bolts.
  21. Slide transmission and jack rearward until input shaft clears clutch housing.
  22. Lower transmission jack and remove transmission from under vehicle.
  23. Insert clutch alignment tool in clutch disc and into pilot bushing. (Tool will hold clutch disc in place when pressure plate bolts are removed)
  24. Remove pressure plate bolts completely and remove pressure plate, clutch disc and alignment tool.
  25. Remove Flywheel

Transmission & Clutch Installation

Installation is the reverse of the removal instructions with particular attention to the following:

  1. Ensure Flywheel has been machined to factory specifications. (DO NOT use old pressure plate with new clutch disc).
  2. Ensure Flywheel, Clutch Disc and Pressure Plate surfaces are free from oil, grease and dust (spray with brake cleaner and wipe with dry paper towel).
  3. Ensure pressure plate bolts are free of oil and dry, apply Locktite to these bolts prior to installing.
  4. Align clutch disc with alignment tool before tightening pressure plate bolts.
  5. Do not force transmission input shaft into new clutch hub upon installation. ( you may have to turn the output shaft to align the input splines).

REMEMBER - Safety, Cleanliness and the Correct Tools are essential for a proper clutch install.

 

Troubleshooting Information

 

Clutch Chatter (Not to be confused with Clutch Rattle)

  1. Flywheel Has Excessive Run-Out.
  2. Fly Wheel Was Not Resurfaced Before The New Clutch Was Installed.
  3. Flywheel Was Resurfaced Improperly Or Has Improper Surface Finish.
  4. Flywheel Has Severe Hard Spots Or Hot Spots.
  5. Flywheel Resurfaced Improperly (I.E. Incorrect Flywheel Step).
  6. Damaged Or Excessively Worn Cv Joints.
  7. Bad U-Joints In Drive Shaft Or U-Joints Misaligned.
  8. Excessive Backlash In Differential.
  9. Excessive Drive-Line Angle.
  10. Bad Leaf Springs, Bushings Or Mounts.
  11. Improper Gear Ratio Versus Tire Diameter.
  12. Defective Pressure Plate And/Or Disc.
  13. Disc Has Inadequate Or No Marcel (Not Enough Cushion Between The Friction Facings).
  14. Oil Or Grease Contamination On Clutch Facings.
  15. Worn Or Damaged Clutch Linkage.
  16. Bent Cover Assembly And/Or Disc .
  17. Improperly Tuned Engine.
  18. Worn Or Damaged Engine Mounts Or Transmission Mounts.

 

Clutch Slippage

  1. Improper Clutch Adjustment Free play.
  2. Quadrant Not Reset Properly Or Is Faulty (On Ratchet Cable Type Linkage. Systems).
  3. Incorrect Throw out Bearing Is Being Used (Too Long).
  4. Clutch Assembly Contaminated With Grease/Oil.
  5. Clutch Not Fully/Properly Seated In.
  6. Flywheel Not Surfaced And Disc Has Been Glazed.
  7. Clutch Assembly Not Designed For The Application.
  8. Clutch Assembly Not Designed For Specific Type Of Use (Racing/Competition, Etc.).
  9. Clutch Not Adequate For Horsepower/Torque Of Application .
  10. Incorrect Gear Ratio To Tire Diameter .
  11. Clutch Assembly Has Lost Facing Material From The Disc.
  12. Clutch Assembly Has Failed Or Is Defective.
  13. Flywheel Surfaced Improperly (I.E. Incorrect Flywheel Step).
  14. Damaged Or Worn Throw out Bearing Collar.
  15. Damaged Or Bent Pressure Plate Assembly And/Or Disc.

 

Poor or Notchy Shifting

  1. Improper Clutch Release Caused By Faulty Linkage And/Or Improper Adjustment.
  2. Improperly Installed Shifter.
  3. Improperly Adjusted Shifter Or Shift Linkage.
  4. Damaged Transmission Parts (Bent Shift Fork, Etc.).
  5. Worn Transmission Synchronizer Rings.
  6. Improper Transmission Lubricant (Check Factory Service Manual For Proper Fluid Type And Viscosity).
  7. Pilot Bushing/Bearing Binding On Input Shaft.
  8. Clutch Disc Hub Rubbing Flywheel Or Flywheel Bolts.
  9. Damaged Or Defective Pressure Plate Torque Straps.
  10. Bellhousing Misalignment