Pilot Bearing

This procedure covers removal and replacement of the pilot bearing, which requires removing the transmission and clutch assembly to access the bearing located in the center of the flywheel.

Warnings

Tools required

Parts

• Pilot bearing × 1 — Use OEM or quality aftermarket bearing
• Clutch disc × 1 — Replace if contaminated or worn
• Pressure plate × 1 — Replace if contaminated or worn
• Transmission input shaft seal × 1 — Replace during reassembly
• Transmission gasket/RTV sealant × 1 — Check application specifications

Fluids

• Mopar ATF+4 (transfer case) — 4.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect both battery cables, negative first
4. Raise vehicle and support securely on jack stands at frame rails
5. Remove skid plates if equipped
6. Allow exhaust system to cool completely if vehicle was recently driven

Procedure

1. 1

   Remove transfer case and transmission crossmember
   Drain transfer case fluid into drain pan. Mark front and rear driveshaft flanges for reinstallation alignment. Disconnect front and rear driveshafts at transfer case and secure out of the way. Disconnect shift linkage, vacuum lines, and electrical connectors from transfer case. Support transfer case with jack or stand. Remove transfer case to transmission mounting bolts and lower transfer case away from vehicle. Support transmission with transmission jack. Remove transmission crossmember mounting bolts and remove crossmember.
2. 2

   Disconnect transmission components
   Disconnect electrical connectors from reverse light switch, vehicle speed sensor (or disconnect speedometer cable on early models), and any other sensors on transmission. Disconnect shift linkage at transmission. Remove clutch slave cylinder mounting bolts and secure cylinder out of the way without disconnecting hydraulic line. Disconnect exhaust system hangers and lower exhaust as needed for clearance.
3. 3

   Support engine and remove transmission
   Place floor jack with block of wood under engine oil pan to support engine weight. Ensure transmission jack is properly positioned and secured under transmission. Remove transmission to bellhousing bolts working from top and bottom. Carefully slide transmission rearward on jack, ensuring input shaft clears clutch disc. Guide transmission down and out from under vehicle. Inspect input shaft for damage or wear.
4. 4

   Remove clutch assembly
   Mark pressure plate and flywheel relationship with paint marker for reinstallation reference. Gradually loosen pressure plate bolts in a crisscross pattern, turning each bolt 1-2 turns at a time to prevent warping. Remove all pressure plate bolts and carefully remove pressure plate and clutch disc. Inspect clutch disc for oil contamination, excessive wear, or damage.
5. 5

   Remove pilot bearing
   Inspect pilot bearing in center of crankshaft flange for wear, roughness, or damage. Insert pilot bearing puller into bearing bore. If using slide hammer with internal puller, expand jaws inside bearing race. Apply steady force to extract bearing from flywheel. If bearing is stubborn, apply penetrating oil around bearing edges and allow to soak, then retry extraction. Clean bearing bore thoroughly with clean rag once bearing is removed.
6. 6

   Install new pilot bearing
   Verify new pilot bearing matches old bearing dimensions. Lightly coat outside diameter of new bearing with high-temperature grease. Position bearing with sealed or shielded side facing outward (toward transmission). Use pilot bearing installation tool or old input shaft to drive bearing squarely into crankshaft bore. Drive bearing until it is fully seated against the shoulder in the crankshaft bore. Verify bearing is seated evenly and spins freely without binding. Verify bearing is seated evenly and spins freely without binding.
7. 7

   Inspect and prepare mating surfaces
   Inspect flywheel surface for heat checking, cracks, or glazing. Check flywheel runout if resurfacing is suspected. Clean flywheel face and pressure plate mounting surface with brake cleaner. Inspect transmission input shaft splines for wear or damage. Replace input shaft seal in transmission bellhousing. Verify clutch fork and pivot ball are in good condition and properly lubricated.
8. 8

   Install clutch assembly
   If installing new clutch disc and pressure plate, verify correct parts for application. Lightly coat input shaft splines with high-temperature grease (do not over-lubricate). Position clutch disc on flywheel with larger hub side facing transmission (marked 'flywheel side' typically faces flywheel). Insert clutch alignment tool through disc and into pilot bearing to center disc. Position pressure plate over disc, aligning marks made during removal if reusing. Install pressure plate bolts finger tight.
9. 9

   Torque pressure plate and verify alignment
   Tighten pressure plate bolts gradually in crisscross pattern, making several passes to bring bolts to final torque specification. Typical torque is approximately 30-45 ft-lbs for 5.9L Cummins application, but verify with the service manual and clutch manufacturer specification. Verify clutch alignment tool moves freely in pilot bearing and can be removed without force. Double-check disc is centered before removing alignment tool.
10. 10

    Reinstall transmission
    Apply thin film of high-temperature grease to input shaft splines. Verify clutch fork is properly positioned. Position transmission on jack and align with engine. Carefully guide input shaft through clutch disc and into pilot bearing, rotating transmission output shaft slightly to align splines. Do not allow transmission weight to hang on input shaft. Push transmission forward until bellhousing seats against engine block. Install transmission to bellhousing bolts and tighten in crisscross pattern. Typical torque is 40-45 ft-lbs but verify with service manual.
11. 11

    Reinstall clutch slave cylinder and linkages
    Reinstall clutch slave cylinder to bellhousing and torque mounting bolts. Reconnect shift linkage to transmission. Reconnect all electrical connectors to transmission sensors. Reposition and secure exhaust system with hangers.
12. 12

    Reinstall crossmember and transfer case
    Position transmission crossmember and install mounting bolts. Torque crossmember bolts to specification. Clean transfer case and transmission mating surfaces. Apply new gasket or RTV sealant as specified. Position transfer case on jack and align with transmission output shaft. Install transfer case to transmission bolts and torque to specification (typically 30-40 ft-lbs). Reconnect transfer case shift linkage and any electrical connectors (manual-shift transfer cases do not use vacuum lines).
13. 13

    Reinstall driveshafts and refill fluids
    Align driveshaft marks made during removal and install front and rear driveshafts to transfer case flanges. Torque driveshaft bolts to specification. Refill transfer case with the specified fluid (typically Mopar ATF+4 for later models; verify correct fluid for model year) until fluid reaches fill plug level, approximately 2 quarts. Reinstall skid plates if equipped.
14. 14

    Final checks and test
    Remove jack stands and lower vehicle. Reconnect battery cables, positive first. Start engine and verify no unusual noises. Test clutch pedal feel and engagement. Check for fluid leaks around transmission and transfer case. Test drive vehicle to verify proper clutch operation, smooth shifting, and proper transfer case operation in all ranges.

Reassembly

1. Apply thread locker to critical fasteners as specified in service manual
2. Ensure all driveshaft bolts are torqued properly to prevent vibration
3. Verify transmission is fully seated against engine before torquing bolts
4. Do not overtighten pressure plate bolts; follow crisscross pattern to prevent warping
5. Replace any fasteners that show signs of damage or excessive corrosion

Verification

• Clutch pedal should have normal resistance and return fully to rest position
• Clutch should engage smoothly without chatter or slipping under load
• All gears should shift smoothly without grinding or resistance
• No fluid leaks visible at transmission, transfer case, or slave cylinder
• No abnormal noises from transmission or clutch area during operation
• Transfer case should shift smoothly between 2WD, 4WD High, and 4WD Low
• Test drive and verify proper operation under normal driving conditions and light load

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