Dodge Ram 1997 5.9L NV4500 5 Speed Clutch Installation

1997 Dodge Ram 3500 5.9L Cummins, NV4500 5 speed manual transmission. This video shows the replacement of the clutch, flywheel, master cylinder, slave cylinder, bell housing alignment inspection and flywheel runout inspection. Serviced and presented by Gary Croyle. For instruction bulletins and additional videos by our part number go to www.clutchtechsupport.com

[@thegreers6]

Fantastic video! Years worth of experience and expertise packed into 33 minutes and well worth the time it takes to watch. Thanks for taking the time to make the video and post it!

[@stevehardeman7209]

The most informative and thorough video I have seen , this will surely assist me in the morning . I have this job waiting for me in my shop . Thanks Steve .

[@rosejacobs9856]

I know this video has been up awhile but, I have a 2000 5.2l magnum that has to have this done. Very informative and I enjoyed watching. I understand that gas and diesel are different but a lot of the mechanics and techniques are the same as well as chassis parts. Very thankful that I found this. It is a perfection clutch and flywheel that is going back in the truck. Thanks again for doing a very good job on instructing and teaching.

[@jacobg6528]

Thank you for the continuation of over complication for no reason.

[@RiggyRonnie]

Very well done! Thank you for sharing some of your knowledge on putting these things together the right way!

[@Eric2300jeep]

I've done a few clutches in my time but, I'm glad I watched this as a refresher! Learned some things I didn't know! Thanks man!

[@perfectionclutch]

No problem! Glad it was helpful

[@madbodhi]

Came across this as I was searching for swapping info on a 6bt/nv4500 into my 78 W250 crew.Very well done and informative.Thank you very much for taking the time to make and post this.

[@GregDelR33]

Great video!!! I have a 95 2500 with the NV4500 in it. One cold morning I stepped on the clutch pedal hard and heard a "pop". Immediately I had very little clutch grab. Not having the time or warm place to do it, I took it to Amco. They swear it's just the clutch. I let them replace it. $1300 later, it still has a soft pedal and grabs really high with a brand new clutch. That clutch disc explodes in about 3000 miles. (to be continued)

[@josephfranciamone5741]

Great information, and very well presented. Thanks for sharing your pro-knowledge with the masses! Now if only I had a proper transmission jack... ;)

[@marcelinohernandez6492]

thank you very much master mechanic, for showing us some of his wisdom as many nesecitamos experts like you, continue to help more people, I'm sure they are happy with their videos as I do.

[@josephnovella3589]

Great video. Super informative with great guides and input on how these systems work together.

[@bronzebeard5890]

I wish I lived close enough to have this man work on my truck.....I'd gladly pay him an asinine amount of money, there isn't a shop near me that puts half the effort he does and shop time is about 100/hr locally.

[@salcas8190]

That possibly why the major manufa tires of HD trucks have discontinue manual transmission?

[@thefuzy1]

Great informative video! Just starting a swap fro 47RH to NV4500 in a 95 Dodge diesel 4x4. Should be interesting. I'll call if needed. Thank you

[@DaytonCarCare]

Thanks for the upload. Very informative. Having issue with a 1500 4x4 truck, will try the bleed process again before removing the tranny to do a inspection. Owner said the previous "shade tree" mechanic may have done a botched job on the clutch. I found he only had one bolt in the CPS which then broke on the fly wheel then caused a "no start" issue. Who knows what else he did poorly. The clutch pedal is dead also. Maybe air or throw out came off fork.

[@zman4ish]

if i read you wrong which i may have, and you have an automatic and you want to do a manual swap for your 1500 5.9, then you could use an nv4500 you will just need a different bell housing to match up to your gas engine (this will be very easy because in dodge 2500 trucks they used the nv4500 behind gas and diesel)

[@Rancidkidd]

This video is great and really helped me understand how to properly assemble the clutch assembly. I got quoted for $700 in labor to have the job done, instead I burned a few Saturday's in my drive way in the cold speaking curse words. It was slightly challenging to get the transmission back in because the angle of the input shaft needs to be at the same degree as the clutch ...so a little adjusting of the tranny jack and patience got her in. Also I needed to use a 2x4 and a piston jack to spread the frame in order to get the crossmember back in. The whole job sucked but was relatively straightforward.

[@fortmcmurraycash]

Good work man...very good pointers for young fellas

[@mynameisspence]

I have a question. How did you set up your dial indicator to check the runout inside the bellhousing? I'm currently trying to figure this one out. trying to find center with my dial set. Also, I did a flywheel face reading, I got a max reading of .003 between the 5'o clock and 9' o clock position. The acceptable tolerances i've read are .005 to .008, so I'm thinking that I'm safe in that regard. Unless you think otherwise. I cleaned the heck out of everything and torqued the flywheel bolts to spec, cleaned off the flywheel surface beforehand.

[@gates3522]

thanks Gary. i will try a couple of those scenarios then give you a call during the work week,

[@zman4ish]

in dodge 1500 trucks, they did not have the nv4500 behind the engines. you will either have to get a new transmission or you could get an adapter plate but i would not recommend that because if your putting a high torque diesel engine in your 1500 truck, the stock transmissions will not be able to take that much power very easily and you run a high risk of blowing your trans. i would highly recommend getting an nv4500 to put behind your cummins

[@noisawsome]

Good video but I was looking for the installation and that was the only part you skipped..

[@montwolfman]

you neglected to instruct correcting the -19" off center issue. I figure 8" toward the 12 o clock is needed...will the two hollow dowel pins allow moving the adapter plate that much?

[@PopsHowTo]

Man, I wish I could take my truck to this guy...

[@John-fi1dl]

Great stuff How much can you safety resurface a 5.9 flywheel.

[@MM0SDK]

I guess I'll just have to hope my mechanic pays this amount of attention to lubrication when my Corolla goes in for a new clutch next Tuesday. I don't really feel comfortable asking him to grease well as it's what a clutch replacement should always involve. Almost seems like telling him how to do his job, but I've sneaked a thin film of grease in the release bearing grease channel. Living in the UK, with most people driving manual trans with intense stop/start driving, clutches have to be nice and smooth, for me at least.

[@MM0SDK]

***** thanks the reply. As you say, not all vehicles have the same lubrication requirements, which seems to be the case with my Corolla on looking through a service manual. The manual states no grease on the collar for the bearing at all, only on the fork. So, will be cleaning off the film i applied.... Silly me. Lol

[@will79601]

@perfectionclutch oh i see i am replacing the clutch now new pilot bearing resurfaced dual mass flywheel and i know not to use the bolts to suck it in so to say thanks for replying back

[@salcas8190]

Is it possible the manufacture of HD trucks with standard transmission discontinued manual trans., due to the future lack of skilled, experienced, mechanic's??

[@ryder4721]

Great Video

[@Evanbmt]

My NV4500 won’t let me put it into any gear when I come to a stop and place it into neutral on a stop light. Then I’ll try to put it into 1st and I can’t it won’t let me in any gear.... some times I can force it into 4th then it will let me go into 1st to start and move... any help on what’s going on?

[@ferebeescott211]

A buddy of mine had the same problem when we installed his new clutch but it popped after the installation was complete. His problem? Somehow he broke 1 of the ears of the plastic clutch master cylinder where it bolts to the firewall. Once we replaced it the clutch felt better than new.

[@midnightthreat7011]

My retaining clip came out. Don't know how the fork was sitting on the bench when I picked it up the clip was out. I fought with it till I lost my religion. How do you snap it back in.

[@jdimpact8454]

Will a 99 dodge Dakota sport 5 speed 3.9 have those sleeves u talk about could cause alignment damage if they're missing?

[@Cmoney534RS]

hey, great tutorial, got a question, i have a auto 5.9 magnum that im putting a NV3500 behind it, now the auto crank wont have a pilot bearing, will an oem replacement bearing work or will i have to drill the hole bigger, im getting the parts this weekend so im going to find out anyway but any advice would be helpful

[@Milkmans_Son]

Zero mention of this in the 1996 GM factory service manuals or the transmission/transaxle/transfer case unit repair manual.

[@t_train3796]

Great video. Appreciated the detail. You mentioned high temp wheel bearing grease for the splines but did not mention the type for the pivot points, bearing, and sleeve. I assume the same type of grease is fine?

[@2large43]

How do you bleed the system with out a blessed screw??

[@DanielRead]

The service manual says on diesel engines if housing bore runout exceeds 0.015 inch, the clutch housing/transmission adapter plate must be replaced. If that bell-housing needs to come down ten thou how do you go about doing that?

[@marmonridecontrol3690]

Daniel, I actually replaced the engine to trans adapter plate and bell housing on this truck in this video. Just pay attention to the dowel sleeves and clean surfaces. But this is the NV4500 5 speed. The NV5600 and G56 6 speed bell housing is part of the transmission cases, not so easy to R&R those housings. Not so easy to determine if out of spec either. Gary

[@sergioramirez-rs2xi]

muy buen vídeo y buen trabajo saludos desde Acapulco, guerrero,México

[@Marty59143]

Great video thanx

[@DieselDoesIt603]

Is it normal for the slave cylinder push rod to always have a load on the clutch fork/ throw out bearing causing it to always spin? When I insurt the slave into the bell housing i have to use some force to compress the internal slave spring. I've tryed cracking the bleeder to release any built up pressure, and no luck, I also shortened the push rod by a 1/2". I've also bench blead the system like shown in video. The system is the 98-02

[@ralphpostell9439]

i have a 03 dodge ram 2500 changed the slave cylinder with the master and slave kit pre bled but my buddy forgot to tighten the bolts on the slave cylinder when i tried to shift it would not shift and then i noticed the bolts loose on the slave cylinder so i re tightend the bolts but nothing i pulled the slave out and the retaing tabs wore broke do you think i got air in the system and if so how do i bleed it with out those tabs holding the rod in after i bleed it

[@ferebeescott211]

I'm working on a project using one of these cummins in a chevrolet and I have been buying pieces as money allows. I have a question about the bolts mating the bellhousing to the engine plate. The bellhousing has 1/2" threaded holes all the way around yet the engine plate was 3/8" threaded holes. Is there sleeves I am suppose to install in the bellhousing holes or is there special bolts I'm suppose to be using?

[@gates3522]

i have a 99 2500 cummins 5 speed NV4500. i just started having a issue with a noise that only happens when i am stopped with the clutch pedal down. truck shifts normal and no slipping. The noise almost sounds like drum brakes slighty pressed and dragging with a growl. Any ideas?

[@JohnnyQuestFishing]

I was watching this video and I have a question and hopefully you get this.... I heard from some guys that it is possible to put the clutch backwards.. what do they mean by that... I have yet to find a video that ever talks about that.. they say if you put it backwards the clutch won't catch.. is this true for 2000 Dodge Ram 1500 3.9L V6 RWD Manual TRans ???

[@ethandart8384]

I have the same setup in a 2001 the nv3500 I had the master and slave cylinder go I thought it was the clutch at first and yes it will not catch if its backwards

[@treyhaberman]

The clutch disc usually has flywheel or transmission side stamped on it to show which way to install it.

[@GregDelR33]

$1200 more and I still have a soft clutch pedal and high grab. I thought I diagnosed it as a hydraulic system. The master cylinder would leak a tiny amount of dot3 when pedal was pushed. I installed a new hydraulic system which said not to bleed it. I still have a weak pedal and high clutch grab. I've stopped driving it. Maybe a bent release fork? I'm at a loss. Any help would be very much appreciate. Where is your shop? Maybe I'd just take it to you if close enough. Thanks

[@will79601]

@perfectionclutch is it possible to install the clutch pack on the flywheel install it on the trans and install the transmission with the clutch pack on it sorta like an automatic torque convertor

[@paconsky91]

its the diesel trany different from the gasoline one? i want to put a manual to my 1500 5.9 and i want to know if the NV4500 fits. can you guys help me on this please?

[@will79601]

@perfectionclutch well i understand that after i got it out lol can i put the clutch assembly on the flywheel and install it on the transmission then install the transmission like a torque convertor on an automatic?

[@josephsaiz2690]

Show parts for bearing Fork on bellhousing transmission NV 4500 what parts for bearing Fork

[@Hunter42392]

Looking to buy a second gen ram 1500 again are 5 speed manuals transmissions more reliable then the automatics with the 5.9?

[@eerie_genetics8459]

Dodge2017 As long as you’re stock power levels they’re both decent transmissions. Obviously the automatic has more parts and is more complicated therefore more expensive usually to fix. The auto can be built up decently to handle more power. The NV3500 would be cheaper to fix. I have a 92 Dodge with the 5.9 Cummins and I have the bigger NV4500 and has handled 600-800ft-lbs of torque well.

[@will79601]

does this apply to an 05 dodge ram 2500 cummings 6 speed manual

[@josesijoseorijinal1]

como purgar cilindro maestro del cloch de dacota

[@chadblechinger5746]

Sometimes it is ALL in the name. How long has this one been in orbit guys?

[@1988diesel]

What about the 5th gear problem.

[@SuperDutyCummins]

wish i had a truck lift when i had to do my clutch :(

[@GregDelR33]

Oh and it has minor gear clash now...and also not enough torque to use four wheel drive without the clutch slipping. Maybe the release bearing is bad? I really don't know....Ammco was worthless. They acted like I neglected the first clutch. Yet I heard it clacking..almost sounded like valve tap. So my guess is it was poorly aligned and maybe cheap parts. I dont't know. I don't have the funds to have anyone else look at it really. Very upsetting.

[@wbb55]

#4 on Ranger clutch video. You wrote S/C, shoulda been M/C.

[@1stooge782]

Have ever seen sudden syncro failed in 97 dodge 1500

[@wessendorf15]

do you guys think you coucld make a video shot work on the 5.2 doge ram 4x4 with the nv 3500 tranny?

[@Stealthcookie]

wont get far without the clutch disc installed

[@mattshafer8934]

Over thinking hahaha

[@littelt11]

Waste of 33mins