Throw-Out Bearing

Replace the throw-out bearing (clutch release bearing) by removing the transmission, clutch assembly, and installing a new bearing on the input shaft retainer.

Warnings

Tools required

Parts

• Throw-out bearing (clutch release bearing) × 1 — Use OEM specification
• Clutch kit (disc, pressure plate, pilot bearing) × 1 — Recommended replacement with throw-out bearing
• Transmission drain plug crush washer × 1 — Use OEM specification
• Flywheel bolts × 1 — Often TTY (torque-to-yield), use new bolts if specified
• Transmission fluid × 1 — Mopar MS-9224 or 75W-90 GL-4

Fluids

• transmission_manual — 4.2 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake.
2. Disconnect negative battery cable to prevent accidental starter engagement.
3. Raise vehicle using floor jack and support securely on jack stands at all four corners. Ensure adequate working clearance underneath.
4. Remove rear wheels if additional clearance is needed for exhaust or driveline work.
5. Allow exhaust system to cool completely if vehicle has been recently operated.

Procedure

1. 1

   Drain transmission fluid
   Position drain pan under transmission drain plug located on bottom of transmission case. Remove drain plug and allow fluid to drain completely (verify capacity against service manual; T56 typically holds approximately 3.4 quarts). Inspect drained fluid for metal particles or clutch material contamination. Reinstall drain plug with new crush washer. Inspect drained fluid for metal particles or clutch material contamination. Reinstall drain plug with new crush washer.
   Torque spec

   Drain Plug34 Nm (25 lb-ft)
2. 2

   Remove driveshaft
   Mark driveshaft and differential yoke alignment with paint or punch marks for reinstallation reference. Remove the 4 U-joint strap bolts at the rear differential. Support driveshaft and slide rearward to disengage from transmission output shaft. Remove driveshaft from vehicle. Inspect output shaft seal for leaks.
3. 3

   Disconnect shift linkage and electrical connections
   Disconnect shift linkage from transmission shift arms. On the 1992 Viper 6-speed manual (Borg-Warner T56), the shifter is a direct tower-mounted unit; remove the shifter from inside the vehicle or unbolt the shift tower from the transmission rather than disconnecting external shift-rod linkage. Disconnect reverse light switch electrical connector. Disconnect vehicle speed sensor connector if equipped. Disconnect clutch slave cylinder hydraulic line at transmission bell housing (if internal slave cylinder type) or remove slave cylinder mounting bolts (if external type) and secure cylinder out of the way without disconnecting hydraulic line if possible to avoid bleeding.
4. 4

   Support engine and transmission
   Place floor jack with wood block under engine oil pan to support engine weight. Position transmission jack under transmission with safety chains or straps. Adjust transmission jack to just contact transmission case and take slight load off transmission mounts.
5. 5

   Remove transmission crossmember
   Remove transmission mount-to-crossmember fasteners. Remove crossmember-to-frame bolts (4 bolts total). Lower transmission jack slightly and remove crossmember from vehicle. Inspect transmission mount for deterioration.
6. 6

   Remove exhaust components as needed
   Remove or lower exhaust system components interfering with transmission removal. On the 1992 Viper, this typically requires disconnecting exhaust hangers and lowering side pipes or disconnecting at collector flanges. Support exhaust components with mechanics wire to prevent damage.
7. 7

   Remove transmission-to-bell housing bolts
   Remove all transmission-to-bell housing mounting bolts. On the T56 transmission, remove the transmission-to-bellhousing mounting bolts (verify exact count and torque against the Viper service manual). Note bolt length and location as they may vary. Support transmission weight on transmission jack throughout this process. Note bolt length and location as they may vary. Support transmission weight on transmission jack throughout this process.
8. 8

   Remove transmission from vehicle
   Verify all electrical connections, linkages, and fasteners are disconnected. Carefully slide transmission rearward on transmission jack, ensuring input shaft clears clutch disc and pilot bearing. Keep transmission aligned with engine to avoid damaging clutch disc. Once input shaft is clear, lower transmission jack and remove transmission from under vehicle. Have assistant guide transmission to prevent binding.
9. 9

   Inspect clutch assembly and remove throw-out bearing
   With transmission removed, inspect clutch disc, pressure plate, and flywheel for wear, hot spots, cracks, or oil contamination. Verify the release bearing type first: the throw-out bearing rides on the front bearing retainer (input shaft sleeve). If a mechanical fork-actuated bearing is used, slide it forward off the retainer noting any clips; if a hydraulic concentric slave/release bearing is used, unbolt the slave assembly from the retainer instead. Note the position of any retaining clips or springs. Inspect the fork pivot ball and clutch fork for wear. Check bearing retainer sleeve for scoring or damage.
10. 10

    Remove pressure plate and clutch disc (if replacing)
    If replacing the complete clutch assembly, use flywheel holding tool or have assistant hold flywheel with pry bar through starter opening. Gradually loosen pressure plate-to-flywheel bolts in star pattern, 1-2 turns at a time to evenly release spring tension. Remove all bolts and carefully remove pressure plate and clutch disc. Note clutch disc orientation (flywheel side vs pressure plate side marked on disc hub).
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
11. 11

    Inspect and service flywheel
    Inspect flywheel friction surface for heat checking, cracks, hard spots, or scoring. Measure flywheel thickness if specification is available. Flywheel should be resurfaced or replaced if damaged. Check flywheel bolts if removing flywheel - verify against the service manual whether they are torque-to-yield and require replacement, and confirm the correct torque and any thread-locking requirement. Clean flywheel surface thoroughly with brake cleaner and lint-free cloth before installing new clutch components.
12. 12

    Install new clutch disc and pressure plate
    If replacing clutch assembly, ensure flywheel surface is clean and dry. Install clutch disc with longer hub side (damper springs side) toward transmission, shorter side toward flywheel. Most discs are marked 'flywheel side' or 'pressure plate side'. Place pressure plate over clutch disc and align bolt holes with flywheel. Insert clutch alignment tool through clutch disc hub and into pilot bearing to center disc. Hand-tighten pressure plate bolts in star pattern. Torque pressure plate bolts to the manufacturer-specified value (do not assume the flywheel bolt torque applies) in 3 stages (1/3 torque, 2/3 torque, final torque) using star pattern to ensure even clamping. Remove alignment tool.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
13. 13

    Install new throw-out bearing
    Inspect transmission input shaft bearing retainer for wear or damage. Clean retainer sleeve with solvent. Apply light coat of high-temperature bearing grease to bearing retainer sleeve (do not over-grease as excess will contaminate clutch). Slide new throw-out bearing onto bearing retainer, ensuring it moves smoothly without binding. Install any retaining clips or springs in their original positions. Verify throw-out bearing fingers or contact surface align with clutch fork properly.
14. 14

    Reinstall transmission
    Apply small amount of high-temperature grease to input shaft splines (do not over-apply). Position transmission on transmission jack and raise into position. Align transmission input shaft with clutch disc hub and pilot bearing. Rotate transmission output shaft by hand to align splines while pushing transmission forward. Do not force transmission - if it does not slide in easily, verify clutch disc is centered and splines are aligned. Once transmission is fully seated against bell housing, install and hand-tighten all mounting bolts. Torque mounting bolts to specification in criss-cross pattern.
15. 15

    Reinstall transmission crossmember and mounts
    Raise transmission slightly with transmission jack and position crossmember. Install crossmember-to-frame bolts and transmission mount fasteners. Torque all fasteners to specification. Remove transmission jack and engine support jack.
16. 16

    Reconnect driveshaft, linkage, and electrical connections
    Install driveshaft, aligning marks made during removal. Install U-joint strap bolts and torque to specification. Reconnect shift linkage to transmission, adjusting if necessary for proper gate engagement. Reconnect all electrical connectors (reverse light switch, speed sensor). Reconnect clutch slave cylinder or hydraulic line. Bleed clutch hydraulic system if line was disconnected.
17. 17

    Reinstall exhaust components
    Reinstall or reconnect exhaust components removed during disassembly. Install exhaust hangers and verify proper clearance from chassis, driveshaft, and fuel lines. Torque exhaust flange bolts if applicable.
18. 18

    Refill transmission fluid
    Remove transmission fill plug. Using fluid pump or funnel with extension, refill transmission with the correct capacity of the manufacturer-specified manual transmission fluid (verify exact fluid spec and quantity against the Viper service manual). Fluid should reach bottom of fill hole. Reinstall fill plug and torque to specification.
    Torque spec

    Fill Plug34 Nm (25 lb-ft)
19. 19

    Final inspection and testing
    Reconnect negative battery cable. Reinstall rear wheels if removed and torque lug nuts to specification. Lower vehicle from jack stands. Start engine and verify no leaks from transmission, clutch hydraulic system, or drain/fill plugs. With engine running and clutch pedal depressed, shift through all gears to verify proper engagement. Test drive vehicle, checking for proper clutch engagement, smooth shifting, and no unusual noises from throw-out bearing or transmission.

Reassembly

1. Reassembly follows disassembly steps in reverse order.
2. Ensure all torque specifications are followed precisely, especially flywheel/pressure plate bolts and transmission mounting bolts.
3. Use new crush washers on drain and fill plugs.
4. Verify proper clutch pedal feel and adjustment after installation - pedal should have 1-2 inches of free play before engagement.
5. Check for fluid leaks after first test drive and recheck fluid level after 100 miles of operation.

Verification

• Engine starts with clutch pedal depressed and transmission in neutral.
• Clutch engages smoothly without chatter, grabbing, or slipping.
• All gears engage easily without grinding or resistance.
• No abnormal noises from transmission or throw-out bearing area during clutch engagement/disengagement.
• No fluid leaks visible from transmission, drain plug, fill plug, or clutch hydraulic system.
• Test drive confirms smooth operation under load with no slippage at high RPM.
• Clutch pedal returns to full up position and has proper free play (1-2 inches before resistance).

More procedures for this vehicle