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replacing a clutch? *Almost there now...

Chevy305

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Sounds like a simple question... :doah:

However, I've never done this before, does anybody have any tips on how to do this?

This is on my 85 K10 305/465/208.

Also while I have the trans and t-case out is there any preventative maintainance I should do?
 
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The tranny and T-case comes out first. Then the pressure plate is unbolted which frees the old clutch disc. Next the flywheel is unbolted from the back of the crank. At this point it's a very good idea to check for any signs of rear main seal leaking. If it's leaking even a little you might as well replace it as you've done 90% of the work for that job already.

Check the flywheel for heat scoring and or cracking. As long as it's not too messed up it can be re-ground. Cost is usually around $30-$50 to have that done.

Re-install the flywheel. It can only go one way as there is a dowel to position it. Use a torque wrench to get the bolts properly torqued.

Most every clutch kit I've bought over the last 15 years has had a dummy input shaft to align the clutch disc during re-assembly. You slide the dummy input into the clutch disc, then slide the small end into the pilot bushing. This holds the clutch disc in position until you get the pressure plate bolted up. The pressure plate bolts should be tightened equally in increments, then torqued.

I then re-install the bell by itself and torque those bolts up. At this point I put the new throw out bearing on the release fork. Make sure it's facing the right way...best to pay close attention to how the old one came apart.

The last part is the hardest part of the job...and that is getting the tranny re-attached. The input must go through the throw-out without dislodging it, then through the pressure plate (without bashing any of the release fingers) and finally the splines must pass through the clutch disc. This is where it can be frustrating.

I specifically bought some extra long bolts that fit in the bell and use them as guides. You get the tranny started, thread in the long bolts and continue. Once you're at the clutch disc the fun begins. If you're smart you'll put the tranny in gear before you start the process, and find a gear that allows you to rotate the tranny using the rear yoke. once you get the input against the disc rotate the tranny a little while gently wiggling and pushing the tranny. Getting it to go through the disc has taken me as little as 5 minutes, and as long as three hours of wrestling.

I prefer using an engine hoist through the tranny tunnel over any sort of macguyver'd floor jack method.

Oh yeah, you'll want to remove the shifter. Twist the retainer collar while pushing down and the shifter will pop right out.

Rene
 
Forgot to add the clutch is marked "flywheel side"...so pay attention to that. You don't want your clutch disc in backwards.

Rene
 
The pressure plate bolts should be tightened equally in increments, then torqued.

This part is important, if you don't tighten the pressure plates slowly and evenly you will warp it (i.e. tighten one bolt a little, then tighten the one opposite it and so on).
 
wow thanks Rene! :waytogo: :bow:

unfortunately, all i have is the floor jack method... but
 
I've done it a few times with the floor jack...be very careful. It's somewhat easy to drop the whole works.

Rene
 
I've done it a few times with the floor jack...be very careful. It's somewhat easy to drop the whole works.

Rene

Thanks for the advice. :bow:

I have an ATV/Motorcycle jack so it should be a lot more steadier than your standard floor jack.
 
Hum motorcycle atv lift, why didnt i think of that! Let me know how it works for you! How high do they go though, not sure if i would be able to get it high enough for my truck.
 
I've pulled mine and did exactly how Rene described. Only problem i had was i couldn't get it to start into the pilot bushing. It could get it to about and inch of going all the way in. after 3 hours of wrestling i had a good idea. I turned themotor over with the key while in neutral. it poped right into place.

May not be the best method but it's worked to 2 times i've put the tranny back in. Just an idea
 
That's why I leave the tranny in gear so I can grab the output and turn it while wiggling the tranny a bit. It really helps get the splines aligned...

Rene
 
Oh yeah, you'll want to remove the shifter. Twist the retainer collar while pushing down and the shifter will pop right out.

Rene

doesn't the shifter have to be 1/2 way into reverse? :confused:
 
It isn't required to be in any gear, but if it isn't in a gear, it makes it much harder to line up the splines.
 
It isn't required to be in any gear, but if it isn't in a gear, it makes it much harder to line up the splines.

I thought it had to be 1/2 way into reverse in order to remove the shifter. Otherwise its impossible to get the shifter back in... :dunno:
 
I thought it had to be 1/2 way into reverse in order to remove the shifter. Otherwise its impossible to get the shifter back in... :dunno:
I think i've always just had mine in neutral...:dunno: can't remember. I don't really pay attention when i do it. it just comes natural i guess
 
Halfway into reverse is where it needs to be to remove the entire top cover...which you don't need to do.

Rene
 
If your gonna pull the tranny from underneath, unbolt the tranny hump from the floor pan. It'll be a lot easier to get the trans in & out without that in your way.
 
it is much easier to reach the clutch, flywheel, etc. through the tranny hump as well
Just did this the other night- better than laying upside down!!
 
I didn't have the luxury of having a removable hump. I had to cut a hole to make my 4-speed work in my Blazer :(

Good info though ;)
 
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