Hello, looking for some guidance. 02 Dakota 3.9L, NV 3500 5 speed 200k. Clutch went out at Xmas time 2019. Was replaced at a local shop with a AutoZone kit. From day one it hasn't acted right. If cold like first few miles it works perfect. Can go 1st to reverse with complete ease. After some time and use it acts like it won't disengage fully. Fights ya to go in gear. If it's shut off it's fine. Plus if it's started in gear when it's acting up it will lunge. At stop lights you can feel the truck wanting to go with the clutch to the floor. In neutral with the clutch to the floor it takes a terrible amount of effort to get into 1st gear. I take off in 2nd a lot. Shop says it must be the hydraulic system, ok replaced that with a Dorman unit. No change. Same shop said it must be a bad one, ok replaced it again with a RinoPac unit and again no change. Tried making the slave cylinder push rod a half inch longer with no change. Any ideas?

 

Clutch master is failing. Are you losing fluid from the hydraulic system?

 

Thanks for the reply. I have been through 3 hydraulic systems. The OEM original one, a Dorman one and a RhinoPac one. None of the 3 leaked or used fluid and all 3 acted the same way. I agree it soyund like a hydraulic issue but 3 with the same result is very odd. Plus they are not easy to change.

 

No. They aren't.

Is the slave cylinder external to the trans?

 

It's mounted on the bell housing. The hydro systems come pre blead and as a full assembly. Plug n play.

 

Yes, the hydraulic clutch systems are a full assembly, at least OEM.

I'd be looking at the pressure plate and disc. I think it unlikely the throwout bearing is the problem.
While it may have fit the flywheel, either or both may not be the correct dimensions.

 

Thanks for the reply. These were gray haired mechanics. I would hope they know to look at the parts and match them up. I remember there was a question whether it would be an 11" or 12" clutch that came out of it. Either way the 12" was the replacement, a 12" did come out and go back in.

 

There is more than just eyeballing the parts. The pressure plate fingers need to be the correct length and if they were resurfaced could cause just what you're seeing. There are lots of variations.

​​​​​​is the fork for the throwput bearing installed correctly and not worn excessively?

I hate to say it but I think you're looking at pulling the clutch assembly.
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I went oem when I did mine. The dealer can look up the correct part by vin.

 

Sounds like it's coming apart to me as well. Problem is the old oem clutch is long gone. Like you said, I have no idea if what is in there now is correct. Appreciate you help.