Clutch Disc

This procedure covers removal and replacement of the clutch disc on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel and manual transmission, requiring transmission removal.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM or heavy-duty aftermarket for Cummins diesel
• Pressure plate × 1 — Use OEM or heavy-duty aftermarket
• Pilot bearing × 1 — Use OEM specification
• Throw-out bearing (release bearing) × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Transmission output shaft seal × 1 — Use OEM specification if damaged
• Flywheel bolts × 8 — One-time use recommended

Fluids

• 75W-90 synthetic gear oil (transmission) — 4 qt
• Mopar ATF+4 (transfer case) — 4.5 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Disconnect both battery cables, negative first
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove skid plates if equipped
5. Place drain pans beneath transmission and transfer case
6. Allow transmission and transfer case to cool if recently driven

Procedure

1. 1

   Drain transmission and transfer case
   Remove the transmission drain plug and allow fluid to drain completely into a suitable container. Remove the transfer case drain plug and drain fluid. If no drain plug exists on transmission, fluid will drain during removal.
2. 2

   Disconnect driveshafts
   Mark the rear driveshaft and front driveshaft flanges with paint or marker for proper reinstallation alignment. Remove the four bolts securing the rear driveshaft to the rear axle yoke. Remove the four bolts securing the front driveshaft to the front axle yoke. Support and remove both driveshafts. Secure transfer case output yokes with plastic bags or tape to prevent fluid loss.
3. 3

   Disconnect shift linkage and electrical connections
   Disconnect the shift linkage from the transmission shift tower. On NV4500 transmissions, remove the shift tower bolts and remove the tower assembly completely. Disconnect the reverse light switch connector, vehicle speed sensor connector, and any other electrical connectors from the transmission. Disconnect the clutch slave cylinder hydraulic line at the transmission (external slave) or remove the slave cylinder mounting bolts (internal slave on later models).
   ℹ️On models with internal slave cylinder, the slave will be accessed after transmission removal. Do not attempt to disconnect hydraulic line if internal type.
4. 4

   Remove starter motor
   Disconnect the starter motor electrical connections. Remove the two or three bolts securing the starter motor to the bellhousing. Carefully remove the starter motor from the vehicle.
5. 5

   Support transfer case and remove crossmember
   Position a transmission jack or support stand under the transfer case to support its weight. Remove the nuts or bolts securing the transfer case crossmember to the frame. Remove the crossmember from the vehicle. Slightly lower the transfer case and transmission assembly to gain clearance for bellhousing bolt access.
6. 6

   Remove bellhousing-to-engine bolts
   Support the transmission with a transmission jack positioned at the mid-point of the transmission case. Remove all bellhousing bolts securing the transmission to the engine block. There are typically 6-8 bolts of various lengths around the perimeter. Note the location of each bolt as they may be different lengths. Remove any ground straps or wiring harness brackets attached to the bellhousing.
7. 7

   Separate and remove transmission assembly
   Carefully slide the transmission and transfer case assembly straight back away from the engine. Keep the transmission level and ensure the input shaft clears the clutch disc and pilot bearing. The assembly is very heavy; use the transmission jack to control the weight. Once the input shaft has cleared the bellhousing, carefully lower and roll the assembly out from under the vehicle.
   ⚠Do not allow the weight of the transmission to hang on the input shaft or clutch disc damage will occur.
8. 8

   Inspect and remove clutch assembly
   Inspect the clutch disc for wear, oil contamination, or damage. Check the pressure plate for hot spots, warping, or cracks. Mark the pressure plate position relative to the flywheel with paint for reinstallation balance. Use a flywheel holding tool or large screwdriver wedged in the ring gear to prevent rotation. Remove the pressure plate bolts in a crisscross pattern, loosening each bolt gradually (2-3 turns at a time) to release spring pressure evenly. Remove the pressure plate and clutch disc.
9. 9

   Inspect flywheel and replace pilot bearing
   Inspect the flywheel surface for heat cracks, hot spots, scoring, or excessive wear. Measure flywheel thickness if there is visible wear (should be resurfaced or replaced if below specification). Using a slide hammer with pilot bearing puller attachment or a bushing removal tool, extract the pilot bearing from the center of the crankshaft. Clean the pilot bearing bore thoroughly with brake cleaner. Install the new pilot bearing using a pilot bearing installation tool or appropriately sized socket, driving it in until it is flush or slightly recessed per specification.
   ℹ️Some models use a pilot bushing instead of a bearing. Verify correct replacement part before installation.
10. 10

    Clean and prepare mating surfaces
    Clean the flywheel face with brake cleaner and a clean cloth. Do not use compressed air due to potential asbestos-like dust. Use a wire brush to clean the pressure plate bolt holes in the flywheel. Inspect the flywheel ring gear for damaged teeth. Clean the clutch fork pivot ball and inspect for wear. Apply a small amount of high-temperature grease to the fork pivot and throw-out bearing contact points.
11. 11

    Install new clutch disc and pressure plate
    Place the new clutch disc on the flywheel with the damper springs facing the transmission (longer hub side toward transmission). Insert the clutch alignment tool through the clutch disc and into the pilot bearing to center the disc. Position the new pressure plate on the flywheel, aligning it with the marks made during removal if reusing the same pressure plate. Install new pressure plate bolts finger-tight. Tighten the pressure plate bolts in a crisscross pattern gradually and evenly to proper specification (typically 30-40 ft-lbs for this application, verify with manufacturer). Remove the alignment tool only after all bolts are fully torqued.
    ⚠Failure to use the clutch alignment tool will result in inability to reinstall the transmission.
12. 12

    Install throw-out bearing and prepare transmission
    If the vehicle has an internal slave cylinder, install the new throw-out bearing onto the new slave cylinder assembly and install as a unit onto the transmission input shaft bearing retainer. If external slave, install the new throw-out bearing onto the clutch fork and secure the fork to the pivot ball inside the bellhousing. Apply a thin film of high-temperature grease to the transmission input shaft splines (very light coating only). Inspect the transmission input shaft seal and replace if leaking or damaged.
13. 13

    Reinstall transmission assembly
    Position the transmission and transfer case assembly on the transmission jack. Carefully raise and align the transmission with the engine. Guide the input shaft through the throw-out bearing and into the clutch disc and pilot bearing. The transmission should slide smoothly into place with light pressure if the clutch disc is properly aligned. Do not force the transmission; if it will not slide in easily, the clutch disc is misaligned. Install all bellhousing bolts and tighten in a crisscross pattern to ensure even seating. Typical specification is 40-50 ft-lbs for bellhousing bolts.
    ⚠️Never use bellhousing bolts to draw the transmission to the engine. This can crack the bellhousing or damage the clutch disc.
14. 14

    Reinstall crossmember and reconnect components
    Raise the transmission and transfer case assembly into position and reinstall the crossmember. Install crossmember mounting bolts and torque to specification. Remove the transmission jack. Reinstall the starter motor and torque mounting bolts to specification. Reconnect all electrical connectors including reverse light switch and vehicle speed sensor. Reconnect the clutch slave cylinder or hydraulic line. Reinstall the shift linkage or shift tower and adjust as necessary.
15. 15

    Reinstall driveshafts and refill fluids
    Reinstall the front and rear driveshafts, aligning the marks made during removal to maintain proper phasing. Torque driveshaft flange bolts to specification (typically 40-65 ft-lbs; verify exact value with service manual for your yoke/flange type). Refill the transmission with the correct fluid type and quantity for the specific transmission (NV4500: ~4 qts Mopar/Castrol 75W-85 GL-4 synthetic; NV5600: ~4.75 qts; G56: ~5.7 qts of specified fluid) through the fill plug until fluid reaches the bottom of the fill hole. Refill the transfer case with the specified fluid (Mopar ATF+4 for NV231/NV241/NV271 units) to the proper fill-hole level; capacity is typically approximately 2.5-3 quarts — verify with service manual. Reinstall fill and check plugs. Reinstall skid plates if equipped.

Reassembly

1. Verify all bolts are torqued to proper specifications
2. Confirm all electrical connections are secured
3. Check that driveshaft alignment marks are matched
4. Ensure transmission and transfer case are filled to proper levels
5. Verify clutch hydraulic system has no leaks (bleed if necessary)
6. Reconnect battery cables, positive first then negative

Verification

• Start the engine and verify no unusual noises from bellhousing area
• Check for any fluid leaks around transmission, transfer case, and hydraulic lines
• With engine running and clutch pedal depressed, shift through all gears to verify smooth engagement
• Test clutch engagement point by slowly releasing pedal in first gear - should engage smoothly without slipping or grabbing
• Perform a test drive to verify proper clutch operation, smooth shifts, and no slippage under load
• Recheck fluid levels after test drive and top off if necessary
• Verify no vibration from driveshafts during operation

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