Pressure Plate

Replace the pressure plate on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine by removing the transmission, inspecting the flywheel, and installing a new clutch assembly.

Warnings

Tools required

Parts

• Pressure plate and clutch disc kit × 1 — Use OEM specification or quality aftermarket for Cummins diesel
• Pilot bearing × 1 — Use OEM specification
• Throwout bearing (release bearing) × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification if equipped
• Transmission pan gasket × 1 — Use OEM specification or RTV sealant
• Flywheel bolts × 6 — Use new TTY bolts if original type

Fluids

• Mopar ATF+4 — 14 qt
• Mopar ATF+4 (transfer case) — 4.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect both battery cables (negative first, then positive)
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove front driveshaft from transfer case (mark yoke orientation)
5. Remove rear driveshaft from transmission (mark yoke orientation)
6. Place drain pan under transmission and drain transmission fluid via drain plug
7. Place drain pan under transfer case and drain transfer case fluid
8. Remove transmission pan bolts and lower pan to drain remaining fluid
9. Disconnect transmission cooler lines and plug to prevent contamination
10. Disconnect electrical connections from transmission (speed sensors, reverse light switch, etc.)
11. Support transfer case with separate jack or stand
12. Remove transfer case to transmission mounting bolts and carefully lower transfer case
13. Disconnect clutch linkage or hydraulic line from bellhousing
14. Remove starter motor to access bellhousing bolts
15. Position transmission jack under transmission with safety chains

Procedure

1. 1

   Remove transmission crossmember and bellhousing bolts
   Remove the transmission crossmember mounting bolts while supporting transmission with jack. Remove all bellhousing to engine block bolts (verify count and locations against the service manual). Note bolt locations as they may be different lengths. Ensure transmission jack is positioned securely under center of transmission.
2. 2

   Separate and lower transmission
   Carefully slide transmission rearward on jack to disengage input shaft from clutch disc and pilot bearing. Pull straight back to avoid damaging clutch disc. Once input shaft is clear, slowly lower transmission jack and remove transmission from under vehicle. Keep transmission level to prevent internal component damage.
   ⚠Do not allow transmission weight to hang on input shaft. This can damage clutch disc, pilot bearing, or bend input shaft.
3. 3

   Inspect clutch assembly and mark pressure plate
   Inspect clutch disc for oil contamination, wear, or damage. Check flywheel for heat cracks, scoring, or excessive wear. Use chalk or paint marker to mark pressure plate orientation to flywheel before removal (usually marked with 'X' or dot). This maintains balance if reusing flywheel.
4. 4

   Remove pressure plate bolts
   Insert flywheel holding tool or large pry bar between flywheel teeth and bellhousing to prevent rotation. Gradually loosen pressure plate bolts in a star pattern, alternating between bolts and loosening each only 1-2 turns at a time to prevent warping pressure plate. Once all bolts are loose, remove bolts completely and carefully remove pressure plate and clutch disc.
   ⚠Pressure plate springs are under tension. Loosen bolts evenly in star pattern to prevent warping or sudden spring release.
5. 5

   Remove and replace pilot bearing
   Inspect pilot bearing in end of crankshaft for roughness, wear, or contamination. Remove old pilot bearing using slide hammer with internal puller or bearing puller tool. Clean pilot bearing bore in crankshaft with brake cleaner and shop rag. Install new pilot bearing using appropriate driver or socket that contacts outer race only. Drive bearing in until flush with crankshaft surface.
   ⚠Do not hammer directly on pilot bearing. Use proper installation tool to prevent bearing damage.
6. 6

   Inspect and prepare flywheel surface
   Inspect flywheel friction surface for heat checking, scoring deeper than 0.030 inches, or hard spots. If flywheel requires resurfacing or replacement, remove flywheel bolts in star pattern using flywheel holding tool. Clean flywheel surface and pressure plate mounting surface with brake cleaner and wire brush. Remove any rust, oil, or debris. If installing new flywheel or resurfaced flywheel, ensure bolt holes are clean and threads are not damaged.
   ℹ️Flywheel minimum thickness specification is typically stamped on flywheel. Do not use flywheel below minimum thickness.
7. 7

   Install flywheel (if removed)
   If flywheel was removed, align flywheel to crankshaft (dowel pin or offset bolt pattern ensures correct orientation). Install flywheel bolts per manufacturer spec (verify whether new bolts are required). Apply thread locker if specified. Insert flywheel holding tool and tighten flywheel bolts in the specified sequence to the manufacturer torque specification (Cummins 5.9L typically uses a high torque value plus angle; consult service manual).
   ⚠Flywheel bolts are often torque-to-yield (TTY) and must be replaced with new bolts. Verify bolt type before reusing.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)
8. 8

   Install clutch disc and pressure plate
   Lightly lubricate input shaft splines with high-temperature clutch grease (do not over-grease). Position clutch disc on flywheel with protruding hub facing toward transmission (away from flywheel). The disc will be marked 'flywheel side' or 'transmission side'. Insert clutch alignment tool through clutch disc and into pilot bearing to center disc. Position new pressure plate over clutch disc, aligning marks made during disassembly if reusing flywheel. Start all pressure plate bolts finger tight.
9. 9

   Torque pressure plate bolts
   Using flywheel holding tool to prevent rotation, tighten pressure plate bolts gradually in star pattern. Make multiple passes, tightening each bolt incrementally until reaching final torque specification. This ensures even clamping pressure and prevents disc distortion. Note: Torque specification for pressure plate bolts is not provided in database; consult service manual or pressure plate manufacturer specifications for the exact torque (heavy-duty Cummins clutches often specify higher values; verify before final tightening). Remove clutch alignment tool only after all bolts are fully torqued.
   ⚠Tighten pressure plate bolts in star pattern with multiple passes to prevent clutch disc warping and ensure proper alignment.
10. 10

    Install throwout bearing
    Inspect bellhousing for cracks or damage. Clean input shaft bearing retainer and throwout bearing contact surfaces. Install new throwout bearing (release bearing) onto transmission input shaft bearing retainer or clutch fork depending on design. Ensure bearing slides smoothly and retention clips engage properly. Lubricate fork pivot point and contact points with high-temperature grease.
11. 11

    Reinstall transmission
    Apply light coat of high-temperature grease to input shaft splines (if not done earlier). Position transmission on jack and carefully raise into position. Align input shaft with clutch disc hub using clutch alignment tool as guide (remove tool when shaft is partially inserted). Rotate transmission output shaft slightly if needed to align splines. Slide transmission forward until bellhousing is fully seated against engine block. Do not force; input shaft should slide smoothly into clutch disc and pilot bearing.
    ⚠If transmission does not slide easily into place, do not force it. Lower slightly and realign input shaft with clutch disc.
12. 12

    Install bellhousing bolts and crossmember
    Install all bellhousing to engine block bolts in correct locations. Tighten bellhousing bolts in star pattern to ensure even seating. Specific torque for bellhousing bolts should be confirmed in the service manual before tightening. Install transmission crossmember and tighten mounting bolts to specification.
    ℹ️Ensure all bellhousing bolt locations are filled and correct length bolts are used. Missing bolts can cause transmission misalignment.
13. 13

    Reinstall transfer case and related components
    Clean transfer case to transmission mating surfaces. Install new gasket or sealant as specified. Raise transfer case into position and align with transmission output shaft. Install transfer case mounting bolts and torque to specification. Reinstall starter motor. Reconnect clutch linkage or hydraulic line. Reconnect all electrical connections to transmission. Install front and rear driveshafts, aligning marks made during disassembly.
14. 14

    Install transmission pan and refill fluids
    Install the transmission drain plug with a new crush washer (if equipped) and torque to specification. This manual transmission does not use a drop pan or pan gasket; fluid is serviced via the drain and fill plugs. Refill transmission through the side fill plug with proper quantity of manufacturer-specified manual transmission fluid (NV4500/NV5600/G56 typically use synthetic manual transmission lubricant, approximately 4 quarts; verify level at fill plug per service manual). Refill transfer case with manufacturer-specified fluid (typically ATF+4, approximately 2 to 2.5 quarts) to proper level; verify with service manual.
    Torque spec

    Transmission Pan Bolts12 Nm (9 lb-ft)

    Drain Plug34 Nm (25 lb-ft)
15. 15

    Reconnect battery and perform initial checks
    Reconnect transmission cooler lines and verify connections are secure. Lower vehicle from jack stands. Reconnect battery cables (positive first, then negative). Start engine and verify no unusual noises from bellhousing area. Check transmission fluid level at the fill plug with the vehicle level and engine off. Check for fluid leaks around pan, drain plug, and cooler lines. Test clutch pedal feel and engagement point before driving.

Reassembly

1. Torque all fasteners to specification in proper sequence
2. Replace all crush washers, gaskets, and TTY bolts as specified
3. Verify all electrical connections are secured and routed properly
4. Ensure driveshafts are installed with alignment marks matched to prevent vibration
5. Double-check transmission and transfer case fluid levels after initial test drive

Verification

• Start engine and verify smooth clutch engagement without chattering or slipping
• Test clutch pedal free play and adjust if necessary (typically 1-2 inches)
• Perform road test through all gears to verify proper shifting and clutch operation
• Check for abnormal noises, vibrations, or clutch slippage under load
• Verify no fluid leaks from transmission pan, drain plug, or cooler lines
• Recheck transmission and transfer case fluid levels after test drive and top off if necessary
• Verify throwout bearing operates smoothly without squealing or grinding noises

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