Did you get the same thickness OD clutchs/clutch pack that you had before? There are at least 2 different sizes as I recall.

 

I got the fricion pack that WIT recommended over the phone, guess I'll have to research that. I just see it being almost out of the question to have to remove a friction. Especially because I'm only .02" from the smallest shim. I'm at a loss, any my ol' lady's gettin grumpy, guess it's time to turn in for the evening. Back at it tomorrow. Thanks again gents.

 

HeyYou, seems to have all the answers... I love it!

Probably late, but it actually is possible to remove the tranny without touching the exhaust.

What is needed is to put a jack under the tranny, remove all fluid lines, wires, and bolts holding the tranny in the truck, and then just roll the tranny back about 5-6 inches until you clear the exhaust pipe that crosses over from driver to passenger side under the tranny. At that point, drop the thing straight down and out and your golden.

4x4 and 35in. tires, you can practically sit in a lawnchair under your truck while you work on it there is so much space. Must be nice...

 

Something is def. wrong. If you could take pictures of each step you took so I can look at each part and see if there is anything I can pinpoint.

 

Ok here we go. I chronicled the teardown and will post quite a few pictures. We'll start with the face of the extension housing face up with the machined bars I was using for my measurements.

 

Removing the round retaining snap ring.

 

Removing pressure plate from O/D clutch.

 

Now onto the frictions and steels...

 

O/D clutch removed.

 

Removing access cover.

Removed.