How do you remove the clutch from a Dodge D-100?

Answer 1

Start by jacking up the truck and putting it on jack stands.Remove the drive shaft by removing the 4 bolts on the u-joint straps.Drain the trans fluid by removing the plug.It saves a big mess in your hair when you lay in it. Remove the speedo cable,shifter linkage,if it is an A833 4speed remove shifter. Support tranny with floor jack and remove crossmember bolts and tranny mount bolts.Remove crossmember ,mark the crossmember so you know which side is which when you reinstall it.Remove the 4 bolts that hold the tranny to bell housing,carefully slide the tranny back and lower it out of the way.Be careful it is heavy ,it helps to have a transmission jack ,but a floor jack will do. Remove the dust shield from the bottom of the bellhousing ,remove the throwout bearing from the fork. Remove the 6 bolts that hold the pressure plate to the flywheel.You have to turn the engine to get the bolts out unless you take the bellhousingoff which means you have take starter off. Lower the pressure plate and clutch out as a unit,noting which way the clutch disc sets in the pressure plate.If your flywheel is not cracked or scored then just clean it with brake clean and some emory paper.You will need an alignment tool to line up the clutch,most kits now have a tool in the kit. Alternate tightening the pressure plate bolts to avoid warping the disc or the pressure plate.Reinstall everything and check your clutch adjustment. Good luck. I did my D-100 a few weeks back,including installing a new front and rear seal and rebuilding the shifter it took me about 5 hours working by myself on jack stands and I am 60 years old.