Clutch Kit

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

Warnings

Tools required

Parts

• Clutch kit (disc, pressure plate, throwout bearing) × 1 — Use OEM specification for Cummins diesel
• Pilot bearing × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Clutch fork boot × 1 — Use OEM specification
• Transmission fluid × 1 — Manual transmission gear oil

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Disconnect both battery cables, negative first
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove skid plate if equipped
5. Drain transmission fluid into appropriate container
6. Remove front and rear driveshafts after marking their positions and yokes for alignment
7. Support engine from above using an engine support bar or chain hoist to prevent tipping when transmission is removed

Procedure

1. 1

   Disconnect transmission external components
   Disconnect the clutch hydraulic line at the transmission slave cylinder. Disconnect all electrical connectors including reverse light switch, speed sensor, and any transfer case connections. Remove starter motor and set aside. Disconnect shift linkage or remove shifter boot and shift tower assembly depending on transmission type (NV4500 has internal tower, NV5600 has external linkage).
2. 2

   Support and remove transfer case
   Place a transmission jack or support stand under the transfer case. Remove the transfer case skid plate mounting bolts. Mark the transfer case to transmission orientation. Remove the transfer case mounting nuts from the adapter studs. Carefully slide the transfer case rearward off the transmission output shaft and lower it from the vehicle. The transfer case weighs approximately 85 pounds.
3. 3

   Support transmission and remove crossmember
   Position transmission jack securely under the transmission with the saddle centered on the transmission case. Apply slight upward pressure to take the weight off the crossmember. Remove transmission mount bolts from the crossmember. Remove crossmember mounting bolts from the frame and remove the crossmember from the vehicle.
4. 4

   Remove transmission to bellhousing bolts
   Remove all transmission to bellhousing mounting bolts. Note and count all transmission-to-bellhousing mounting bolts as you remove them (counts vary by transmission and bellhousing configuration). Note the location of any different length bolts. Note the location of any different length bolts. Remove the bellhousing dust cover bolts and remove the dust cover to access lower bolts if not already removed.
5. 5

   Remove transmission
   With an assistant steadying the transmission jack, carefully slide the transmission straight rearward away from the engine. The transmission must move straight back to prevent binding the input shaft in the clutch disc. Once the input shaft clears the bellhousing, carefully lower the transmission and roll it out from under the vehicle. The transmission weighs approximately 200 pounds for NV4500 or 225 pounds for NV5600.
6. 6

   Inspect and mark pressure plate position
   Inspect the flywheel surface for scoring, hot spots, or cracks. Check flywheel runout if resurfacing is being considered. Use a marker or paint pen to mark the pressure plate position relative to the flywheel for balanced reassembly if reusing the same flywheel. Inspect the clutch fork, pivot ball, and slave cylinder for wear.
7. 7

   Remove pressure plate and clutch disc
   Gradually loosen the pressure plate bolts in a criss-cross pattern, turning each bolt 1-2 turns at a time to release spring tension evenly. This prevents warping the pressure plate. Once all bolts are loose, remove them completely and remove the pressure plate and clutch disc. Do not drop the clutch disc as the friction material can be damaged.
8. 8

   Remove pilot bearing
   Remove the pilot bearing from the end of the crankshaft using a slide hammer with internal puller attachment or a pilot bearing puller tool. If stuck, pack the cavity behind the bearing with heavy grease and use a close-fitting shaft to hydraulically force the bearing out. Clean the pilot bearing bore thoroughly with brake cleaner and a wire brush.
9. 9

   Clean and prepare mounting surfaces
   Clean the flywheel surface thoroughly with brake cleaner to remove all oil, grease, and debris. Wire brush the pressure plate mounting surface on the flywheel. Clean the transmission input shaft splines with brake cleaner and inspect for wear. Replace the input shaft seal in the transmission front bearing retainer if any seepage is evident. Check clutch fork and pivot ball condition and replace if worn.
10. 10

    Install new pilot bearing
    Lightly coat the outer diameter of the new pilot bearing with clean engine oil. Drive the pilot bearing into the crankshaft bore using a pilot bearing installation tool or appropriately sized socket until it is fully seated and flush with the crankshaft bore. Install the bearing in the orientation specified by the bearing manufacturer's markings/instructions (for many sealed pilot bearings the sealed side faces outward toward the transmission); verify before pressing in.
11. 11

    Install clutch disc and pressure plate
    Insert the clutch alignment tool through the clutch disc and into the pilot bearing to center the disc. The clutch disc must be installed in the correct orientation as marked on the disc (typically the side marked 'flywheel side' faces the flywheel and the protruding longer hub faces the transmission). Verify orientation against the markings stamped on your specific clutch disc before installation. Position the pressure plate onto the flywheel, aligning the marks made during disassembly if reusing the flywheel. Install all pressure plate bolts finger tight, then tighten in a criss-cross pattern gradually to specification. Verify the pressure plate bolt torque specification with the service manual or clutch manufacturer for your specific pressure plate; heavy-duty Cummins clutches commonly call for approximately 30-45 ft-lbs. Do not rely on a generic value.
12. 12

    Install throwout bearing and lubricate
    Install the new throwout bearing onto the clutch fork. Apply a small amount of high-temperature bearing grease to the transmission input shaft bearing retainer where the throwout bearing slides. Replace the clutch fork boot if worn or damaged. Verify the clutch fork pivots smoothly on the pivot ball. Apply a small amount of grease to the fork pivot point and slave cylinder contact points.
13. 13

    Reinstall transmission
    Apply a thin coat of high-temperature grease to the transmission input shaft splines (do not over-grease as excess can contaminate the clutch disc). Carefully raise the transmission into position using the transmission jack. Align the input shaft with the clutch disc splines using the clutch alignment tool as a guide. Slide the transmission forward, rotating the output shaft slightly if needed to engage the splines. The transmission should slide fully forward until the bellhousing seats against the engine block. Do not force it or use bolts to draw it in.
14. 14

    Install transmission mounting bolts
    Install all transmission to bellhousing bolts in their original locations, noting any different length bolts. Tighten bolts in a criss-cross pattern to ensure even seating. Remove the clutch alignment tool by reaching through the bellhousing opening or through the inspection cover. Install the bellhousing dust cover.
15. 15

    Install crossmember and transfer case
    Raise the transmission slightly with the transmission jack and install the crossmember. Install crossmember to frame bolts and tighten. Install transmission mount to crossmember bolts. Clean the transfer case input shaft and apply a thin coat of grease. Raise the transfer case into position, aligning the marks made during disassembly. Slide the transfer case forward onto the transmission output shaft and seat it fully against the adapter. Install transfer case mounting nuts and tighten. Install transfer case skid plate.

Reassembly

1. Reconnect all electrical connectors to transmission and transfer case
2. Reinstall starter motor and tighten mounting bolts
3. Connect clutch hydraulic line to slave cylinder and bleed system if line was disconnected
4. Install shift linkage or shifter assembly
5. Install front and rear driveshafts, aligning marks made during disassembly to maintain proper phasing
6. Refill transmission with appropriate manual transmission fluid to proper level
7. Install skid plates
8. Reconnect battery cables, positive first then negative

Verification

• Start engine and verify clutch pedal feels firm with no excessive free play
• With engine running and brake applied, verify transmission shifts smoothly into all gears
• Verify clutch engages and disengages smoothly without slipping or chattering
• Test drive vehicle to verify proper clutch operation under load
• Check for any fluid leaks around transmission and slave cylinder
• Verify no abnormal noises from transmission or clutch operation
• Confirm no driveline vibration indicating proper driveshaft phasing

Related trouble codes on this vehicle

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