Designing and Building a Clutch Release Mechanism for an Eaton Fuller Swapped GMC C3500HD [Part 13]
ฝัง
- เผยแพร่เมื่อ 9 ก.พ. 2025
- Milwaukee Metal Cutting Saw: amzn.to/31Ej50q
I design and build a clutch release mechanism for my Eaton Fuller swapped GMC C3500HD.
Instagram: / waldowelds
Any purchases you make using the links provided help to support the channel at no extra cost to you! As an Amazon Associate I earn from qualifying purchases.
![Cummins/Eaton Swap: Installing the Shifter, Accelerator Pedal, and Brake Pedal [Part 14]](http://i.ytimg.com/vi/-vFOXMajXg8/mqdefault.jpg)
![Cummins/Eaton Swap: Installing the Shifter, Accelerator Pedal, and Brake Pedal [Part 14]](/img/tr.png)
![Attempting a First Drive, But is the Transmission Broken? [Cummins Swap Part 21]](http://i.ytimg.com/vi/QOrbBC7BA5w/mqdefault.jpg)
Who would dislike this? Waldo you are a damn good fabricator.
Thanks, David!
David ,when he said he learned to drive a standard on a 95. I'm thinking he learned a lot of stuff in such short time. I've been welding and fabbing for 40 years and he makes me feel dumb. I like his work and this channel. Glad I found it.
@@WaldosWorld - What's the name of the junk yard?
I would like to do a similar gearbox swap
I am now officially a member of the Awesome Club! (Actually, watching you do the work is awesome!
Waldo you have some of the best videos around, such a pleasure to watch you and give hope to all us who aspire to fix or build anything as amateurs. The range of your projects is great also I like the mistakes that you show and overcome in such a simple way. Keep up the good work......
My friend, you are an absolute genius. I'm not being facetious. I'm an old guy and I've been in the car business my whole life and retired now and you have engineered some not just clever but very sound pieces of equipment and parts. Absolutely great job and I love you videos. I'm binge-watching them now
I keep watching your videos!! You are doing an amazing job!! when I came to the States (from Morocco) my American friends and colleagues (grad students) gave me a strange look when I told them that I fix my car engine myself, and that I can work on anything. We just learn to do a lot of handy things at a young age! I did fix my Prius and Ford many times. But unfortunately, with work and school, it's hard to find time to work on things! I enjoy it! I am based in Ohio, and I would love to know the best Auctions where to buy classic German and American cars & vans & trucks and fix them. Thanks in advance!
Great job of fabbricobbling, Waldo! I’ve built two custom hydraulic clutches previously, and they were both smooth like yours. You’ll love driving with your clutch setup. About the amount of release throw needed, what I did is jack up the back wheels. Then use a ratchet strap to pull the release fork a bit at a time. Try to spin the driveshaft while the trans is in gear. You’ll discover what throw is needed to properly release. I then took that measurement and compared it to the full stroke of the slave cylinder. That gave me the ratio needed, which in your case is the a/b/c/1/2/3. Good luck!
Thanks, Greg! That's approximately how I planned to test it, though I don't have a driveshaft hooked up yet, so I'll spin the parking brake drum and I don't have to jack up the rear end 😎
@@WaldosWorld Right. 😀. I was thinking about my truck where I had the driveshaft already installed, but of course, you haven’t got to that yet on your truck.
You just keep rolling out great quality, interesting and entertaining videos - thanks for all the hours spent making them that way.
love the series, cant wait to watch
Thank you!
Videos are great! Found the series randomly and I’ve been watching nonstop. Your videos are just like a tv show!! Great job Waldo!
Had to do something like this to shorten the throw on an overdrive unit, and while it's not as slick as this, it was definitely one of the more satisfying parts of the swap. Great explanation & illustration!
Thanks!
Excellent design and fabrication of your clutch release mechanism. Professional fabrication shops would be proud of your work.
Thank you!!
This is the first TH-cam video I've ever commented on because I want to thank you for such fantastic content. TH-cam seriously lacks videos as in depth and as interesting as yours for fabrication-related videos. I've seriously enjoyed following along with this series and it's been a huge help for giving me ideas with my swap (eaton 6 speed into 5.9 Ford F800). This truck is going to be super cool when it's done. Cheers!
Wow, thank you so much for the comment, Ben! That F800 sounds like a pretty cool truck too 😎
Brilliant filming !! An education , soon you will be sorting NASA out with there problem solving issues , just shows what can be done , thank you an inspiration to us all !
Haha thanks, Steve!!
Excellent video, that clutch linkage is a great bit of work. 👍
Very nice! Awesome fab skills, and enjoyed the table for the travel and leverage ratios. Reminds me of hvac damper and valve linkage issues I get to resolve in the instrumentation world. Keep up the great work and videos.
Thanks, Scott!
Waldo. Add the word Bushing where you use the word Bearing. I love your work brother!
Thanks! Yeah, bushing is probably a better word for the bronze bushings/bearings 👍
You had my head spinning with all the math and figuring!
I watched your video to the end and I like the way you problem solve, awesome job!
I’ve been following along for a while now and you were right when you said that the videos like the flat bed and gooseneck build bring in the most views. I came for the flat bed videos…
Couple things that have been bothering me, 1) why do you constantly drag your weld? I was always trained to push the weld pool when using solid wire.
2) what’s with the frame on the 3500? It looks like the front half of a 1/2 tonne truck welded to the rear half of the frame from a medium duty truck?
Tremendous fabrication skills...You are very talented.
Thank you very much for the videos and also the invitation to be awesome. Although not quite as awesome as you, I do, at times, exude such awesomeness as to impress even those of mediocre awesomeness. I hope in my journey to total exceptional awesomeness to attain the knowledge and skills of at least an awesome ninja. Although a lofty goal for most I know it’s it’s a mere stepping stone for the properly initiated, motivated, and superior minds such as ours. Nice work Mr Awesome 👍
great to see you use what you have to make it work, that allen key was the right tool to get it done. great job making that clutch pedal
Good job👍
Thank you!
The lever you made for the clutch operation is called a bell crank. Nice work
Cardboard aided design. 😂👍
I’ve been waiting for this one. Awesome work!
Thanks for the patience! Videos on this project should be coming out a bit more frequently now 👍
Well done Waldo. Nice job.
You have definitely inspired me to try new things
Really enjoying this series love the fabrication
Awesome squad unite. Working my way to the elite squad as I full clear every episode 😂
Thanks for watching! 😂
Man its been a while since i saw a video.i enjoyed this video man keep up with the great work 🙏💪
Thanks, Martin! I'm glad to be back on this project!
First off I love how you’ve learned the most important mechanics trick- every tool is either a hammer or punch😂😂😂
Your craftsmanship on that linkage is amazing! Love watching you come up with this stuff!!
For play in the pedal you can also adjust the clutch through the bottom. There should be one 11/16 bolt on the clutch for free play. Have someone hold the pedal down and go under and turn bolt clockwise as if tightening it. If I didn’t explain that well just hit me up and I’ll explain better.
Has Aspen doing her job with patrolling chipmunks etc? She looked ready!
Thank you for sharing another awesome video Waldo!! Stay well.
Hahaha thanks, Pete! 🤣
For the 11/16 bolt, is it inside the transmission bellhousing? I didn't see any bolts like that on the pedal assembly
As for Aspen, yep she's been doing her usual hunting, though I've been leaving her inside most of the time since she gets cold with only one layer of short fur 🥶
@@WaldosWorld hi Waldo. Yes the 11/16 is inside the bell housing. It’ll face rear of the truck. There is only one and unless someone removed it, it’ll have a tag under it stating clutch adjustment.
I’ve seen it on every Eaton transmission I ever dealt with so I can’t imagine it not being there.
I’m still in awe over your bracket. That’s a phenomenal build.
If I can help in any way please don’t hesitate to reach out.
Thanks so much, Pete! I didn't realize you knew so much about these transmissions!
@@WaldosWorld I’ve fixed everything from mowers to tractor trailers, skid steers to payloaders to bulldozers and haul trucks so I know a little. Not everything nor would I say I do but I’ll help where I can.
Love video, can't wait to see what happens next
Thanks, the next video should be out tomorrow. It's gonna be good 😎
Awesome! Another video to this series!
And more to come soon! (hopefully 😂)
Excellent vid Waldo!!! I would suggest that you that you try to download vids more often if you want to build your subs! That truck is gonna be one hell of a sweet ride when your done. Love your attention to detail. Well done!!
Thank you! Yeah, I think I'm going to try doing slightly shorter videos more often
I can't wait to the first test drive keep up the good work love the video
Thanks, Michael!
Great job Waldo. Keep it up.
Thanks! 👍
Awesome video! Watched the whole thing
Thanks for watching!
I'm pretty awesome! Lol just kidding.
I love this series, and i love the amount of patience and detail you put into your work...very much like a me pace!
Thanks for the video...keep em coming :)
Haha thanks John!
Don't know how I'm just being notified now. But FYI other then the chassis, rad cradle, the strip at the bottom and the parking brake drum on the trans, Mostly all the other parts are the same as 2500 and up. Body panels are also the same from 1500. With your petal its probably from a 92-94hd and would have been better to change the whole bracket with everything.
Love the videos, just makes me miss working working on my old fleet.
Thanks! Yeah, that would make sense if the pedal was from a slightly older truck 👍
You are da man, Waldo! Great video. Hope you have a Merry Christmas!
Thanks, Bill! Merry Christmas to you too!
The clutch master slave unit your using is basically the same from your early Ford Ranger truck. I just finished clutch and hydraulic system replacement on my Ford Ranger. Its looking great.. Wait for the next video.
Just discovered your videos love em there so awesome to watch keep up the awesome videos you are awesome to watch as well buddy 👍👍👍👍❤️❤️
You make great quality videos
Thank you! 👍
Where have you been? WOW, I'm awesome, LOL. Missed you for a while, glad your back.
Thanks for watching! I released a couple videos of Dino, though they didn't get a lot of reach on TH-cam 🤷♂️
I can sympathize with your manual transmission learning experience, I learned on a 1982 Chevy S-10 with the horrible cable clutch, close ratio 4 speed and 2.56:1 rear end! To this day it's the most difficult manual I've ever driven, and I've driven quite a few. The easiest I've ever driven is my current daily driver a 2006 Dodge Ram 2500 Cummins G56 (a Mercedes medium duty truck transmission ).
Nice truck! I've driven a lot of VWs and Audis with nice clutches, so I'm a little spoiled to say the least 😬
Absolutely fantastic video keep them coming 💪💪💪💪
Thanks, Cory!
Awesome, good bit of engineering there. In a tight spot like that you can also use a fully mechanical means for transfer of force by using a cable. There are vehicles that use that setup.
Thanks! Yeah, the transmission came with a cable for operating the clutch release, but I decided the hydraulic setup would be a better fit for this application
The cable from the Kodiak/Top Kick with the Caterpillar and Eaton would plug and play work for this as well. Personally I like watching him fab hydraulics,
my first look at your scenario, I would have gone around the cylinder . one shot linkage... but it is fun to play with math. hope the fulcrum is not too much stress.
I was considering something like that, but my concern was that the rod would be pulled to the side unless I somehow stabilized it. After creating a very expensive and complicated design, I said f*** it and went the lever route 😂
Great build series
Thank you!
I watched it all but i dont know about awesome 😊 good job.
theres instructions from GM on how to lie out that line while connected to master and slave attached. It does work and takes a minute of patience to route. That 3 part sysytem is so difficult to bleed as it is id never want to take apart. One good way to bleed is extremely fast pumping of petal by hand also in gm directions
👍Waldo has MORE moves than EX-LAX! 🤣
Great job with the clutch. Hopefully the clutch is fully disengaging.
Thanks! I still haven't tested it yet, but I have plenty of room for adjustment, so I'm confident it'll end up working well 👍
You’re literally building my dream build a Cummins and Eaton
That's awesome to hear! Great minds think alike 😎
Awesome squad is awesome!!
Great video man! Are you planning on coating/painting that assembly? Looking at options for something similar I am doing.
Represent! 💪
I'll probably paint the assembly when I build a flatbed for the truck. I'll be coating the flatbed with an epoxy primer and an industrial urethane topcoat, so it'll be convenient to paint other odds and ends. Oh, I don't know if you saw the video where I painted engine mounts, etc. with POR15 Urethane, but the jury is in and the verdict is that it's garbage. Don't waste your money on it
Impressive. Great job ! 💪👍🏼
Love this build!!
Thank you so much!
Good work!!
Thanks!
I have been waiting for this day... Nice video!
Thanks, Jack!
Thank you
Waldo, impressive engineering! It turned out really nice. I hope it fully disengages or only requires a few adjustments to get there. Any idea on what your planning to do for running your fuel? If I remember correctly, the 24v isn’t fully mechanical like the 12v and I think there is an ECU. This is my favorite project I have seen on TH-cam. I like that it is a c3500hd (we don’t see them much) and I like that it’s a 2wd and I like that it is a manual. A split rear end would be pretty cool as well if your looking for future ideas.
Thanks, Carl! The donor truck has a FASS fuel system that I'm going to swap over. Along with a fuel pressure gauge, that'll help ensure that the injection pump never gets starved for fuel (a common failure point with 24-valves). Also, yep it has an ECU, so I'll have a bit of wiring to do
Good video and narrative.
This is really cool!
Thank you!
Awesome videos! I am at the exact same point. I am placing a 6bt into a rat rod COE truck with a Eaton FSO8406A and was debating on cable or hydraulic. I think you helped me make my decision.
Thank you! Yeah, hydraulic is the way to go 😬
why dont you have more subs this chanel is awesome
Thank you! It's a long path to having lots of subs, but hopefully we'll get there!
Go to tractor supply store and get a hydraulic control cable they have swivel ball joints on both ends then all you need is a bracket to hold cable case at each end
As a heads up, for a auto to ext slave-cyl manual swap on the GMT400s (88-98 gm trucks) the 88-91 clutch hyd system is more service friendly being that it's steel rather than plastic and has brake style lines and bleeders.
Oh, good to know! The ones I got are metal, though it would've been nice if it had a brake style bleeder
Great job
NICE man!!
Thanks, and also thanks for the long-time sub! 👍
wow great job
Good stuff man
Thanks, Keith!
Well done Waldo. How did you learn to to fabricate? Are you an engineer? Or Military training? And I think you get the awesome squad kudos for progressing this truck along with minimalist facilities and doing it pretty much by yourself. Also, it was good to see Dino got some air time too.
Thanks, Scott! I do have a background in computer/software engineering. When it comes to making physical things, I've taken college level physics, but other than that, its just trial and error
Elegant solution
I feel your pain. I learned to drive in a 1989 Ford Ranger. Great little trucks. Horrible clutches.
Did you ever end up adjusting the linkage at all to make the clutch disengage more after your test drive? I’ll be doing a Eaton swap following your videos ! I can’t thank you enough for the detail!
well done
muy util y bien explicado
Gracias!
Just found the channel, binge watching this Cummins swap. Good videos, I'm curious, do you have mechanical engineering training? Seeing your calcs I'm impressed!
That's some great fab work. But wouldn't it be easier to flip the clutch lever and put a pedal through the floor? Or keep it the same and use a clutch cable like a Mack?
My approach definitely was a bit of work. I was originally planning on using the clutch cable that it came with the transmission, but the cable was so stiff that routing it was proving to be a challenge. I think the hydraulic solution has less friction, so the pedal ends up being lighter 👍
love it!!!
Thanks!
Put the Detroit in it.:)
Before I bought the Cummins, I was considering a 6V53, but I was worried about it being a little tight in a pickup engine bay. Also, I wanted a turbo, but a 6V53T would be even tighter. One of these days, I definitely want to swap a Detroit into a road vehicle!
@@WaldosWorld I know what you mean, I stuffed a 4-53T into my 2009 F350. Real tight is an understatement, but it fits and is my daily driver.
Waldo ,you do nice work .. The time you spent doing the math was time well spent , there is a big difference between a truck with a hydraulic clutch much easier on the driver , and a mechanical clutch slowly torturing the driver ...
Thanks! Yeah, the clutch is such an important part of the driving experience that I really wanted to get it right 👌
Im considering doing this to my 2002 GMC c3500 HD WRECKER
You must be a reloader, I spotted some Hogdon power under your bench, looks like maybe H322.
Good eye! 😂
Awesome 👍 Man 😎.
Thanks! 👍
were you able to verify the clutch brake engages when the pedal is fully depressed?
I'll have to double check, but I don't think it has a clutch brake. As for testing for full disengagement, I haven't gotten to it yet, but I'll probably have a helper spin the parking brake drum while I press the clutch pedal
Well Done I like how you are doing this just out of curiosity how much do you have into the rig so far looks like it is going to be a really nice truck.
I just added up as much stuff as I could think of and I'm over $10,000 so far, though I have a lot of parts laying around that I haven't installed yet. I had no idea I've spent so much on this project...ouch! 😂
@@WaldosWorld It adds up in a hurry I know that for a fact 460 BBC Gen 6 build up to a 550 foot lbs torque in a big hurry will over 10000 in just all of the engine parts and the build of it. Did that back in 2013
If you had to make a guess,with a little hammer work, how much body lift could you get by with and leave the cross member alone?
I'd guess maybe 4 inches? Unfortunately, it'd be a much higher center of gravity, which would affect handling
Hey Waldo, just like you I’m awesome too 👍🏻😉🏴
Waldo, loving your videos as I’m about to attempt the same swap in a k3500 Chevy. Do you happen to have any interest in fabbing up another one of those clutch brackets and selling it? I’m sure I could pull it off myself, but I know it will never look/work as well as yours.
Awesome squad!
Love your channel. Nice work. Working on an Eaton swap myself. What master, and slave cylinder did you use?
Walcott thumbs ☝ good video any idea what mpg what axle ratio
So how about free travel for the throw out bearing. Did it have constant pressure on the bearing or did it have free travel before it disengaged
You've got an Exhaust pipe/tip on the Dynahoe now? ;)
Yeah, it came with the exhaust pipe when I bought the machine, it just took me a while to get around to reinstalling it 🤷♂️
Great videos, may I ask why you did not use the nv4500? you are really gonna miss the O/D with that heavy eaton transmission
Yeah, good question. Mostly because the NV4500 doesn't have a speed sensor or a built in parking brake. As for the lack of an overdrive, I'm planning to change the axle ratio, probably to 3.13, which will give me a decent top speed on the highway. I could also put bigger wheels/tires on it, maybe 22.5s. With the current ratio of 4.63, this thing will be slooooooow 😂
Ooh I see, somw c3500hd come with a nv4500 that has a driveline parking brake too, keep up the good job!
The nv4500 for the HDs came with the drum brake on the back of the trans like the 4l80e you took out. Also the drums should be the same.
I have a ‘99 c3500HD that has a n4500 and 5.13 gears. At first I thought I wouldn’t like the gearing but found to haul what this truck can haul especially taking off that they were necessary. And believe it or not when hauling I wish I had an Eaton fso6406. The nv4500 is great but is not a match for what the truck is capable of. And yes mine has the factory park/emergency break drum on the trans. Waldo made the right choice
The EF FSO6406A or FSO8406A both have an OD gear and are FAR superior to the NV4500. I know a lot of folks use the NVG transmission but there are also a lot of failures with them. In my opinion they have no place in a heavy duty build like this.
What doses the slave cylinder do ? If it works the clutch, what ever happened to the old way ? It worked great .
No your Great.
Have you ever heard of someone putting a Eaton fuller 10spd into a Cummins? What do you think on that?