New clutch, releases at top of pedal travel?? - Dodge Cummins Diesel Forum
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post #1 of 55 (permalink) Old 09-09-2019, 12:40 PM Thread Starter
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New clutch, releases at top of pedal travel??

2004, nv5600 2wd. Just installed a new valair clutch and flywheel. Install went fine other than everything being heavy and doing the work on my back... pulled it out of the barn today and noticed that the clutch releases/grabs way at the top of the pedal travel, so I barely press the clutch to disengage. The hydraulics are less than 1000 miles old, prebled non adjustable system from parts store. Is this due to slightly different dimensions of clutch components overall or did the hydraulics not like being fully extended while removed from the transmission??

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post #2 of 55 (permalink) Old 09-09-2019, 05:37 PM Thread Starter
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Emailed valair and explained my issue. Guy eluded to "item 10 on the list of 12 things to check", clutch fork free travel. If there isn't enough, stop because something is installed wrong...like what?! Flywheel, disc, clutch, throwout bearing. Zero adjustments anywhere. I sure hope I dont have to pull this back out. Drives fine, smooth.
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post #3 of 55 (permalink) Old 09-09-2019, 07:17 PM Thread Starter
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Ok...talking to myself here. Went and pulled the slave out and checked free travel on the shift fork, plenty fine, somewhere between 3/4 and 1 inch.
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post #4 of 55 (permalink) Old 09-09-2019, 07:58 PM
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What clutch did you install? With both of my clutches on my 2 trucks I bought new adjustable hydros. In my mind if the clutch you installed is taller than what it replaced the throw of the slave would be different so you need adjustable master to account. Did the guy at valair say anything about this?

You didnt loose any fluid from the clutch cylinder when it was fully extended did you? When I pulled my last one out the rod came right out of the housing.

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Truckasaurus - 2010 2500 CCSB -sold
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post #5 of 55 (permalink) Old 09-09-2019, 08:16 PM
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Im having the same issue with a new installed dual disk. Disengagement at the top, hard shifting and lurching forward while shifting from a stop. I have adjustable hydro's. I will check clutch fork freeplay tomorrow and might stack a few washers up between bellhousing and slave to see if im getting too much travel. Doesnt make sense to me but im not very smart.

1998 12v, 4x4, Club Cab, Carli, Thuren, BlueTop, Core 4x4, BD Diesel, PDD 5x.012, South Bend
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post #6 of 55 (permalink) Old 09-09-2019, 08:20 PM
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98 sounds like your clutch isnt fully disengaging hence why it jumps when you go to put it in gear. I'd think you need more travel not less. Have you tried adjusting your clutch pedal?

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post #7 of 55 (permalink) Old 09-09-2019, 08:53 PM
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That is what I thought too. I did adjust the rod out further, to the point it was probably an inch and half or so above the brake pedal but all it did was bring my release up higher and even though I got more travel, it did not seem to do anything else. I read some folks say that they were told to cut off 1/4" of the slave rod, which again seems backwards to me, but what do I know. I followed southbends hydraulic testing procedures and could shift through the gears.
https://www.southbendclutch.com/reso...aulic-testing/

1998 12v, 4x4, Club Cab, Carli, Thuren, BlueTop, Core 4x4, BD Diesel, PDD 5x.012, South Bend
2012 Laramie Longhorn, EFI by Ryan, Carli, Thuren
1995 Dually, Weston's 5x.016, 4k GSK, 5" FloPro, 255/85r16 Toyo M/T, Goerend, ARP, 60# Springs, BW 62/65/14, BW 75/96/1.10, Isspro, Fass 125, BDP Sump, 7mm DV's, 751 HP 1883 FP Torque on NOS
1998 P-Pumped 24v, 4x4, NV4500 swap
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post #8 of 55 (permalink) Old 09-09-2019, 09:07 PM
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That does seem counterintuitive. Please let us know the results.

Scooty Puff Sr - 2016 3500 CCLB
Truckasaurus - 2010 2500 CCSB -sold
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post #9 of 55 (permalink) Old 09-09-2019, 09:29 PM Thread Starter
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I installed their HD single disc. Like I mentioned I have the recommended freeplay in the clutch fork valair calls for. I feel like some adjustment would help me a lot but I sure dont want to set these new hydros on the shelf and spend 300 more bucks for that adjustment. No fluid lost when doing the work. I cracked the cap earlier today and some fluid spewed out. I attributed that to the system being machine bled and filled to absolute capacity...I dunno.
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post #10 of 55 (permalink) Old 09-10-2019, 12:31 AM Thread Starter
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Well, something isn't right. Shifting at 2000rpm tonight I noticed a definite vibration in the clutch pedal. Stick out of gear and holding rpm there I could feel the vibes throughout pedal travel. At idle and low rpm its smooth. Hard to ignore your foot tickling every time you shift. Guess I'll be pulling this thing back out.
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post #11 of 55 (permalink) Old 09-16-2019, 06:35 PM Thread Starter
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Still cant come to any conclusion on this pedal travel issue, or the vibration in the pedal. I'm halfway suspecting a brand new bad TO bearing. I can press the clutch with my hand and as soon as it tightens up (1/8-1/4"), I can feel feedback through the hydraulics from what has to be the TO bearing as theres nothing else moving in that system.
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post #12 of 55 (permalink) Old 09-16-2019, 07:52 PM
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Did you make sure fork in good shape, right position so dimples contact bearing properly, part number down to left?
Grease on TO bearing grove and input shaft?
Clutch disk in right ?

04 QCSB HO Automatic
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