My 90 T4R sr5 (22re 5spd 4wd w/ 31" tires) had a catastrophic engine failure about a month ago which lead to a motor swap. I sourced a very nice 22re with about 27,000 original miles on it from a dolphin (motor home). Since the swap I've put about 60 miles on the truck and I just noticed a major problem with my 4wd system.

In 4 low im slipping bad.. I shouldnt say slipping because it implies a clutch problem, but thats deffinetly what it feels like. If I dump the clutch in low I get inital 'grab' but then the rpms come up like hell but the truck doesnt go any where like the clutch is slipping. In 2wd or 4Hi it doesnt seem to replicate the effect. Any thoughts?

As some quick background info... With the motor swap a brand new AISIN clutch kit was used (rockauto.com AISIN Part # CKT022 ) and a new bruteforce flywheel. I honestly don't know when the last time the Transfer case fluid was changed so I'll be doing that tomorrow, but as of right now I know it is full. Also my 4x4 indicator like no longer comes on but Ive verified that the ADD axle is engaging, the hubs are lock and I am getting power to both front and rear wheels.

I cant stand to redo work so Im hoping some one has some insight that doesn't involve me having gotten a bad clutch kit from the distributor.

Any and all input appreciated.

 

it's only in 4wd?

have you tried bleeding the clutch system yet?

 

Yeah its only in 4wd low range and I bleed the clutch system three days ago and the pedal still feels awesome... no evidence of losing pressure anywhere. A buddy suggested replacing the slave cylinder for the clutch but Im not sure that would help since i dont appear to be losing pressure any way

 

did you clean the mating surfaces of the clutch with acetone before install.

 

Doesn't go anywhere realistically? Or melodramatically?


Oh, and read my location...

 

I think you snapped a synchro ring on the 4LO and you are bouncing off the gear synchro teeth and popping out.

You broke something in the transfer case, better pull that puppy before you are buying gear sets. But then again it maybe to late :-(

 

I have a similar issue but only in 4wd hi my clutch slips pretty bad in 1st-3rd. doesnt slip in 4low and continues to slip in 2wd for about 20 minutes until the flywheel cools. any ideas besides my clutch going out? sorry to resurrect an old thread haha truck is an 81 4x4

 

You are using a stock pressure plate. Go to marlincrawler and get the 1200 or 1500 pound clutch setup. Stock is only 900 pounds and its just not enough.

 

I've never had a stock clutch slip. I can see wanting a heavier clutch if you do a lot of rock-crawling where you're slipping the clutch a lot, but for normal use the stock clutch should work fine. If it doesn't, there's something wrong with the parts, the installation, the adjustment, or some oil has crept in from somewhere.