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Question that may or may not have anything to do with your issue. I know there is a short and tall throwout bearing for the GM stuff. Which one do you have?
 

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Discussion Starter #262 (Edited)
Question that may or may not have anything to do with your issue. I know there is a short and tall throwout bearing for the GM stuff. Which one do you have?
Good question! I removed the transmission and verified the disc flat side is toward the flywheel. I don't have a clue!
Here is what I ordered. It is the same as what I had before.
I did not use the throw out bearing that came with the kit. It is partial plastic. I used the OEM one.-ACDELCO Clutch Release Bearing. They looked the same size.
I found a site with some information. You are correct there is a short and tall throw out bearing. Also, there is a adjustable pivot ball. I was thinking maybe the pivot ball is too short. I am trying to locate the old one I removed. Also, I replaced the pivot ball so thinking maybe the pivot ball is too short. Wouldn't that make a difference how far the fork presses into the pressure plate.
 

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Discussion Starter #263
Good question! I removed the transmission and verified the disc flat side is toward the flywheel. I don't have a clue!
Here is what I ordered. It is the same as what I had before.
I did not use the throw out bearing that came with the kit. It is partial plastic. I used the OEM one.-ACDELCO Clutch Release Bearing. They looked the same size.
I found a site with some information. You are correct there is a short and tall throw out bearing. Also, there is a adjustable pivot ball. I was thinking maybe the pivot ball is too short. I am trying to locate the old one I removed. Also, I replaced the pivot ball so thinking maybe the pivot ball is too short. Wouldn't that make a difference how far the fork presses into the pressure plate.
I did not remove the pressure plate yet but from the pictures you can tell the flat side is next to the flywheel. Pivot is same size as old. The only difference is the TO that came with the kit is maybe an 1/8 smaller in diameter. Why is it not releasing?
129189

129190

129191
 

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Discussion Starter #265 (Edited)
With the info you have given I am kinda stumped. 1 more dumb question. Is there fluid in the transmission?
That is the first thing I checked. Makes no sense. It was working fine other than the TO issue. I don't understand how but do you think the LUK TO would make a difference? Do I need to remove the pressure plate and reinstall? Don't know what else to do! Could the new pressure plate be defective?
 

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Discussion Starter #267
Motohead,
I was looking for specs on your nv3500 install on the TDI forum. What clutch kits did you use? Which adapter kit from Everguy did you purchase? Flywheel? I purchased the stock GM 153 tooth 1987+ flywheel/flexplate (one piece rear main seal) kit. I didn't purchase a new flywheel. Mine was from an old corvette. Maybe its needs resurfacing or better replacing with a newone Still having issues with it grinding when attempting to reverse.. I have primed and primed and clutch feels solid not spongy. Anyway to take measurements to verify all is correct?
 

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So its not uncommon to have a crunchy reverse engagement on a NV3500 especially if the clutch is dragging a bit. It is a synced reverse so it shouldent though.
I used a stock LUK clutch for a 4.0 powered wrangler as the dodge adapter is the pattern for a 318 v8 witch includes the 4.7 and the v6 in the dakota. the flywheel is for a 4.0 wrangler as well. I started with the new stock 4.0 flywheel (28lbs)? as its supercheap new and only a 1/4 inch smaller than the stock dakota. about 20k miles in I switched over to a 43lbs flywheel from centerforce for a 4.0 I forget the part number but its in my tdiclub build thread. FYI a Dodge and chevy NV3500 is esentually the same just slight gear racio and bell housing stuff. I thing next trans Id like to try is the NSG370 as the gear spread would be perfect and it shouldent rattle in idle as bad as the NV3500. I am just into 100K miles on this same clutch.
 

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Discussion Starter #269
I'm trying to determine if I have the correct pressure plate and disk. The LuK 04-021 Clutch Kit is what Matt suggested I install. The first transmission I installed, I had to add to the slave rod to get it to release. From what I've ready, that is most likely why the TO did not last no more that 20,000 miles. The adapter plate I purchased uses 153 tooth flywheel. Does yours?
Here are specs.
Brand:Luk Clutch

Manufacturer's Part Number:04-021

Part Type:Clutch Kits

Product Line:LuK Clutch Kits

Summit Racing Part Number:LUK-04-021


UPC:670774029530

Clutch Usage:Stock replacement

Clutch Disc Quantity:Single

Flywheel Included:No

Input Spline Quantity:10

Input Shaft Diameter:1.125 in.

Disc Diameter (in):10.375 in.

Disc Diameter (mm):264mm

Disc Material:Organic
 

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Discussion Starter #270 (Edited)
Finally located the issue with my transmission. Adapter plate was loose. In fact, the holes had wallowed out and I had to order another plate. It appears Randy no longer owns the business and was sold to a fab business. I ordered to the new plate 1, 2 and no hub. I had a machinist repair the hub, it had wallowed also. My original plate had two starter holes but the new plate has one. As I was installing the tranny I noticed the dowel pin was missing from the plate. I tried installing the dowel from the older plate but the dowel that fits the plate was to small. I contacted the company he said I needed part Pioneer Dowel Pin part number PG653. Anywhere local I can purchase this? Shouldn't the dowel come with the plate
 

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Discussion Starter #272
yea you need to red loctight all the bolts. little diesel will shake them loose if you dont. Napa has that dowel.
yea you need to red loctight all the bolts. little diesel will shake them loose if you dont. Napa has that dowel.
Great! It will take two for it to arrive from Canada. I will check with them Saturday. Most likely closed tomorrow... I red loctight them. I think I received the wrong bolts. Either they bottomed out or the flywheel hit the bolt heads. The new plate bolt holes are countersunk which is what the original plate should have been.
 

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Discussion Starter #273
Great! It will take two for it to arrive from Canada. I will check with them Saturday. Most likely closed tomorrow... I red loctight them. I think I received the wrong bolts. Either they bottomed out or the flywheel hit the bolt heads. The new plate bolt holes are countersunk which is what the original plate should have been.
Something I did not know since I don't install transmissions for a living is there should be two dowel pins. On the original adapter I received there is only one. It is located in the top left corner driver side. According the NV3500 specs, there should be two dowel pins.
 

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Discussion Starter #274 (Edited)
The new adapter does not have two starter ports to choose from. I can't get the muffler pipe mounted to the turbo at the bottom. Any ideas? If I leave this bolt out, I am going to have an exhaust leak.
130099


Original and New adapter:
130100
 

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Discussion Starter #276
That worked but it is eighth from the bolt. A pity to get the starter to destination with exhaust pipe installed. Now how am I going to keep the heat away the starter. Previously, I made a stainless steel heat shield that covered the round part of starter. Now I need a shield between the start end and turbo. Shave off some of the bolt head?
 

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you have a stock turbo and manifold? Call northwest and let them know. Send them a pic of your old adapter plate. thats to close.
 

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Discussion Starter #278
you have a stock turbo and manifold? Call northwest and let them know. Send them a pic of your old adapter plate. thats to close.
I have the stock turbo and manifold. I have already talked to them. On the the new plate they provide one port for a starter. My previous plate had two and I used the lower port which was perfect. He said no was using the lower port. I can't see why they would delete the lower port. How much money are they saving? My machinist was going to add the port but if you look at the new plate, they added an extra hole near where the second port exist which is where the start bolt goes.. He thought we might warp the plate by filling in the hole so we could tap a hole for the starter to mount. Northwest are redesigning the plate and adding 1/2 inch bolts instead of 3/8. I don't know what else they are adding.
 

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Discussion Starter #279
I have the stock turbo and manifold. I have already talked to them. On the the new plate they provide one port for a starter. My previous plate had two and I used the lower port which was perfect. He said no was using the lower port. I can't see why they would delete the lower port. How much money are they saving? My machinist was going to add the port but if you look at the new plate, they added an extra hole near where the second port exist which is where the start bolt goes.. He thought we might warp the plate by filling in the hole so we could tap a hole for the starter to mount. Northwest are redesigning the plate and adding 1/2 inch bolts instead of 3/8. I don't know what else they are adding.
Pickle Rick says the BHW manifold will work. What do you think? I gotta come up with something, No way the starter will last that close to the starter?
 
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