I am not an auto mechanic

When you own a classic car, you tend to adapt to it's individual nuances. It is not uncommon for an owner to have to jiggle a key to get the ignition to turn, or slam a door with a lifting motion to ensure the door is indeed closed. Up until a few weeks ago I thought the fact that my car shook a little in reverse and shimmied at high speeds was all part of it's character. It never crossed my mind that these were signs that my clutch was burning out. I thought it was part of what made my truck my truck. That was until a shop test drove it and told me that the clutch had seen better days. This made me sad. Even sadder when I was told a clutch replacement would cost me roughly $2500.

Now here is the part where things get interesting. I was about to throw down my one not maxed out credit card to have the job done, when my internet friend Jeff (more on internet friends later) said to me, "Hey, I know how to change a clutch. It's easy. I will fly down from Northern California and help you do it." I was a bit skeptical but since a person I only knew through the internet said I could do it, I figured why not. The idea of saving a ton of money didn't hurt either.

The project started with me ordering some parts: clutch, throw out bearing, transfer case seal kit. transmission seals, real main seal, cross seals, torque wrench, a tarp (didn't want to ruin the floor), and lots of new fluids.

Jeff showed up to my house on Wednesday and I promptly made him go with me to the doctor to have my thyroid checked out. See Barry Rides for more info on that. After I knew he was sufficiently creeped out, we started work on the truck. The first thing was full disassembly. This included the following:

Floor and Transmission Cover Removal - We removed the floor to make it easier to maneuver under the truck. We removed the transmission cover and stick, so the transmission could be removed without being caught on anything.

Exhaust Removal - The exhaust is in the way of the transmission so it has to come out. This is of course is where I learned about budgeting for unforeseen issues. I ended up breaking two exhaust studs which meant I had to remove the passenger side manifold, which meant I had to buy new studs and all new exhaust seals. You will notice that even my dog is disgusted with this project. What was I thinking?

Driveshaft Removal - The driveshafts attach the transfer case to the axles. Since the transmission and transfer case come out as one, they had to be removed. Another great place to break a bolt.

Transmission and Transfer Case Removal - You need to remove the transmission to get to the clutch. This is the point where I really regretted letting a person I only knew through a message forum come over my house. The transmission and transfer case weigh a good four million pounds. We used a jack and some wood to gently lower it to the ground after removing all the bolts.

Clutch Removal - With the transmission out of the way, we were able to see the wear at the center of the clutch. We removed the clutch and flywheel. The clutch went in the trash and the flywheel was set aside for resurfacing.

Oil Pan and Cross Seal Removal - The oil pan had to come out to replace the cross seals. The cross seals were leaking on the clutch which caused the clutch to prematurely wear and slip.

With everything out, we began the process of draining all the fluids, replacing the seals, and installing the new parts. For the most part it went well, but I have to admit I was scared shitless when it came time to install the transmission. When we removed it, gravity helped. During reinstallation I think luck was the only thing on our side. You need to line up the input shaft and these dowels on the bell housing to get it all to fit. Don't ask, I don't know where the dowels are either.

Here is the shocking part. Once we got it all back together and full of fluids, the truck started and ran like a champ. The difference in the way it drives is night and day. I am beyond happy. Would I ever do it again. Absolutely not. Am I happy that I have douchey bragging rights that I undertook such a huge job and was able to get it work. You know it!!!