However, if you're determined to do it yourself, here's a *general* outline. This is not a complete guide, and you'll need a repair manual specific to your truck's year, engine, and transmission for detailed instructions and torque specifications. Improper torque can damage components and lead to serious failure.
1. Preparation:
* Safety First: Disconnect the negative battery terminal. Use jack stands, not just a jack, to support the truck safely. Wear safety glasses and gloves.
* Gather Tools and Parts: You'll need a comprehensive set of tools, including various sockets, wrenches, a clutch alignment tool, a torque wrench, a transmission jack (absolutely essential), possibly a flywheel grinder/resurfacer (depending on flywheel condition), and of course, the new clutch kit (clutch disc, pressure plate, throwout bearing, pilot bearing, possibly a new flywheel). Consult your repair manual for the specific parts you need.
* Repair Manual: Obtain a factory service manual or a reputable aftermarket repair manual specific to your truck. This is crucial for step-by-step instructions, torque specifications, and component diagrams.
2. Removal:
* Drain Transmission Fluid: Completely drain the transmission fluid.
* Disconnect Components: Disconnect the driveshaft, clutch cable (or hydraulic lines), and starter motor.
* Remove Transmission: This is the most challenging part. You'll need to support the transmission with the transmission jack, unbolt it from the bellhousing, and carefully lower it. This often involves removing various components to gain access.
* Inspect Flywheel: Check the flywheel for scoring, warping, or cracks. If it's damaged, it needs to be resurfaced or replaced.
3. Clutch Replacement:
* Remove Old Clutch: Remove the old pressure plate, clutch disc, and throwout bearing.
* Inspect Pilot Bearing: Inspect the pilot bearing (located in the crankshaft). Replace it if it's damaged or worn.
* Install New Clutch: Install the new pilot bearing (if replacing), then the new clutch disc, using the alignment tool to ensure it's properly centered. Carefully install the new pressure plate, tightening the bolts to the specifications in your repair manual. Use a torque wrench!
* Install New Throwout Bearing: Install the new throwout bearing.
4. Reassembly:
* Install Transmission: Carefully raise the transmission back into position using the transmission jack, aligning it with the bellhousing. Bolt it securely, again using the correct torque specifications.
* Reconnect Components: Reconnect the driveshaft, clutch cable (or hydraulic lines), and starter motor.
* Refill Transmission Fluid: Refill the transmission with the correct type and amount of fluid.
* Bleed Hydraulic System (if applicable): If your clutch is hydraulic, you'll need to bleed the system to remove any air bubbles.
5. Testing:
* Test Drive: After reassembly, carefully test drive the truck, checking for proper clutch engagement and disengagement.
Important Considerations:
* Torque Specifications: Incorrect torque can lead to catastrophic failure. Always use a torque wrench and follow the specifications in your repair manual.
* Alignment Tool: Using a clutch alignment tool is crucial to prevent damage to the clutch disc and pressure plate.
* Transmission Jack: A transmission jack is essential for safely removing and reinstalling the transmission.
* Professional Help: If you're unsure about any step, seek professional help. This is a complex repair with potential for serious injury or damage if done incorrectly.
This is a simplified overview. You absolutely must consult a repair manual specific to your 2002 Dodge Ram pickup for detailed instructions and torque specifications. Improper repair can lead to serious damage to your vehicle and potential injury. Again, if you lack experience, take it to a professional.
