Clutch Kit

Complete clutch kit replacement on the 1992 Dodge Viper V10, including transmission removal, pressure plate and clutch disc replacement, flywheel inspection, and hydraulic system service.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM specification or performance equivalent
• Pressure plate assembly × 1 — Use OEM specification or performance equivalent
• Pilot bearing × 1 — Use OEM specification
• Release bearing (throwout bearing) × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Transmission drain plug washer × 1 — Use OEM specification
• Bell housing gasket × 1 — Use OEM specification if gasket equipped

Fluids

• Mopar MS-9224 or 75W-90 GL-4 — 4.2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Raise vehicle and support securely on jack stands at all four corners at frame contact points
4. Remove both rear wheels to access driveline components
5. Allow exhaust system to cool completely if vehicle was recently driven

Procedure

1. 1

   Drain transmission fluid
   Position drain pan under transmission. Remove the transmission drain plug from the bottom of the transmission case using appropriate socket. Allow fluid to drain completely. Inspect drained fluid for metal particles or unusual debris that may indicate additional transmission damage. Install drain plug with new washer and torque to specification. Do not fully tighten yet as transmission will be removed.
   Torque spec

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

   Remove driveshaft
   Mark the driveshaft and rear differential flange relationship for proper reinstallation alignment. Remove the bolts securing the driveshaft to the rear differential flange (verify count against factory documentation). Support the driveshaft and slide it rearward to disengage from the transmission output shaft. Lower and remove the driveshaft. Inspect the rear U-joint and yoke for wear. Place a plastic bag over the transmission output shaft to prevent fluid loss.
3. 3

   Disconnect exhaust system
   The exhaust system must be lowered or disconnected to provide clearance for transmission removal. Disconnect the exhaust pipes at the manifold flanges or at the first available slip joint aft of the manifolds. Support the exhaust system with wire or a stand to prevent damage. On some Vipers, removing the complete exhaust system back to the catalytic converters provides the best access.
4. 4

   Disconnect shifter mechanism and electrical connections
   Working from underneath, disconnect the shift linkage at the transmission. This typically involves removing a roll pin or retaining clip and sliding the linkage off the transmission shift lever. Disconnect the reverse light switch electrical connector on the driver side of the transmission. Disconnect the vehicle speed sensor connector if equipped. Label all connections for proper reinstallation.
5. 5

   Disconnect hydraulic clutch line
   Locate the hydraulic clutch line connection at the bell housing slave cylinder. The Viper uses an external slave cylinder mounted on the bell housing that actuates the clutch release fork. Disconnect the hydraulic line at the fitting on the bell housing. Be prepared for hydraulic fluid spillage. Cap or plug the line to prevent contamination and fluid loss. Inspect the line for damage or wear.
6. 6

   Support transmission and remove crossmember
   Position a transmission jack under the transmission and secure it with a safety chain or strap. Raise the jack slightly to take the weight off the crossmember. Remove the crossmember mounting bolts (typically 2-4 bolts depending on configuration). Remove the crossmember. Verify the transmission is securely supported before proceeding.
7. 7

   Remove starter motor
   Locate the starter motor on the driver side of the bell housing. Disconnect the starter electrical connections (positive cable and trigger wire). Remove the bolts securing the starter to the bell housing (verify exact count against factory documentation). Carefully remove the starter motor and set aside. Inspect starter mounting surface for damage.
8. 8

   Remove bell housing bolts
   Remove all bell housing-to-engine block bolts. The Viper V10 bell housing/transmission is secured with several bolts around the perimeter (verify exact count against factory documentation). Use a combination of standard and deep sockets to access all bolts, as some may be in recessed locations. Note the location of any different length bolts or bolts with brackets attached. Keep bolts organized for proper reinstallation.
   Torque spec

   Bell Housing Bolts68 Nm (50 lb-ft)
9. 9

   Remove transmission assembly
   With the transmission jack properly positioned and secured, carefully slide the transmission rearward away from the engine. The transmission input shaft must clear the clutch disc and pilot bearing. Move slowly and keep the transmission aligned with the engine to avoid binding. Once the input shaft is clear of the clutch, lower the transmission and roll it out from under the vehicle. The transmission weighs approximately 90 pounds, ensure adequate support throughout the process.
10. 10

    Inspect and remove pressure plate
    With the transmission removed, the clutch assembly is now visible. Inspect the pressure plate and clutch disc for wear patterns, hot spots, or damage. Mark the pressure plate and flywheel relationship if reusing the pressure plate (not recommended). Insert a clutch alignment tool through the clutch disc to support it. Gradually loosen the pressure plate bolts in a star pattern, turning each bolt 1-2 turns at a time to release spring pressure evenly. Once all bolts are loose, remove them completely and remove the pressure plate and clutch disc.
    ⚠Pressure plate springs are under significant tension. Loosen bolts gradually in star pattern to prevent warping the pressure plate or flywheel.
    Torque spec

    Pressure Plate Bolts27 Nm (20 lb-ft)
11. 11

    Inspect flywheel and remove if necessary
    Inspect the flywheel surface for heat checking (blue discoloration), cracks, hard spots, or scoring. Minor scoring can be resurfaced, but deep grooves or heat damage requires replacement. If flywheel removal is necessary, use a flywheel holding tool to prevent rotation. Remove the flywheel bolts in a star pattern (verify exact bolt count against factory documentation). Note that flywheel bolts are often TTY (torque-to-yield) and should be replaced if removed. If the flywheel is to be resurfaced, mark the flywheel to crankshaft position before removal to maintain balance. Measure flywheel runout with a dial indicator if available; runout should not exceed 0.005 inch.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
12. 12

    Remove and replace pilot bearing
    The pilot bearing is pressed into the center of the crankshaft and supports the transmission input shaft. Remove the old pilot bearing using a slide hammer with internal puller attachment or a suitable puller tool. Clean the pilot bearing bore in the crankshaft thoroughly. Install the new pilot bearing using a bearing driver or socket of appropriate diameter, driving it squarely into the bore until it seats at the proper depth (typically flush or slightly recessed). Ensure the bearing is driven straight to avoid cocking in the bore.
13. 13

    Clean and prepare mounting surfaces
    Clean the flywheel mounting surface on the crankshaft and the flywheel bolt holes using a wire brush or thread chaser. Remove any oil, dirt, or old thread locker. Clean the pressure plate mounting surface on the flywheel using brake cleaner and a clean cloth. Inspect the crankshaft flange for damage or burrs. Apply a thin coat of medium-strength thread locker to the flywheel bolt threads if reinstalling the flywheel. Ensure all mating surfaces are clean and dry.
14. 14

    Install flywheel (if removed)
    If the flywheel was removed, align it to the crankshaft using the alignment marks made during removal or the factory dowel pin. Install the flywheel bolts hand-tight. Use a flywheel holding tool to prevent rotation. Torque the flywheel bolts in a star pattern to the specified value. Torque the flywheel bolts to the factory-specified value; verify against factory documentation whether these bolts are torque-to-yield and require an additional angular rotation.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
15. 15

    Install clutch disc and pressure plate
    Place the clutch disc on the flywheel with the damper springs facing the transmission (disc hub protrudes 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 over the clutch disc, aligning any balance marks or dowel pins. Install the pressure plate bolts hand-tight. Verify the clutch alignment tool moves freely, indicating proper disc alignment. Torque the pressure plate bolts gradually in a star pattern to the specified value, making several passes to seat the pressure plate evenly. Leave the alignment tool in place until the transmission input shaft is installed.
    Torque spec

    Pressure Plate Bolts27 Nm (20 lb-ft)
16. 16

    Install release bearing and prepare transmission
    Install the new release bearing (throwout bearing) onto the transmission input shaft bearing retainer. On the Viper's external slave cylinder system, the release bearing slides onto the transmission input shaft bearing retainer and engages the clutch release fork. Ensure the release bearing slides smoothly on the input shaft retainer. Inspect the transmission input shaft splines for wear or damage. Apply a thin coat of high-temperature grease to the input shaft splines (do not over-grease as excess can contaminate the clutch). Install the new input shaft seal into the transmission front bearing retainer if included in the kit.
17. 17

    Install transmission assembly
    Position the transmission on the transmission jack and secure it with safety chain or strap. Raise the transmission into position, aligning it with the engine. Carefully guide the transmission input shaft through the release bearing and into the clutch disc splines, using the alignment tool as a guide. Do not allow the transmission weight to hang on the input shaft. If the input shaft does not slide easily into the clutch disc, rotate the output shaft slightly to align splines. Once the input shaft is fully engaged, push the transmission forward until the bell housing seats against the engine block. Remove the clutch alignment tool once the transmission is partially engaged.
    Torque spec

    Bell Housing Bolts68 Nm (50 lb-ft)
18. 18

    Install bell housing bolts and starter
    Install all bell housing-to-engine block bolts in their original positions. Start all bolts by hand to ensure proper thread engagement. Torque the bell housing bolts to specification in a cross pattern. Install the starter motor, securing it with the 3 mounting bolts. Reconnect the starter electrical connections (positive cable and trigger wire). Ensure all connections are tight and properly routed.
    Torque spec

    Bell Housing Bolts68 Nm (50 lb-ft)
19. 19

    Install crossmember and remove transmission jack
    Raise the transmission slightly with the transmission jack to align the mounting points. Install the crossmember and secure it with the mounting bolts. Torque the crossmember bolts to specification. Carefully lower and remove the transmission jack once the crossmember is fully secured and the transmission is properly supported.
    Torque spec

    Mounting Bolts23 Nm (17 lb-ft)
20. 20

    Reconnect hydraulic clutch line and bleed system
    Reconnect the hydraulic clutch line to the bell housing slave cylinder fitting. Torque the fitting to prevent leaks but avoid over-tightening. Fill the clutch master cylinder reservoir with fresh DOT 3 brake fluid. Bleed the clutch hydraulic system by having an assistant pump the clutch pedal and hold it down while you open the bleeder valve at the external slave cylinder on the bell housing. Close the bleeder before releasing the pedal. Repeat until no air bubbles appear in the fluid. Maintain fluid level in the reservoir throughout bleeding process.
21. 21

    Reconnect shifter and electrical connections
    Reconnect the shift linkage to the transmission shift lever, securing it with the roll pin or retaining clip. Verify the linkage moves freely through all gears. Reconnect the reverse light switch electrical connector. Reconnect the vehicle speed sensor connector if equipped. Verify all electrical connections are secure and properly routed.
22. 22

    Reconnect exhaust system
    Raise the exhaust system back into position and reconnect it at the manifold flanges or slip joints. Install new gaskets at the manifold flanges if disconnected at that location. Secure all exhaust hangers and clamps. Ensure adequate clearance between the exhaust and driveshaft, transmission, and body components.
23. 23

    Install driveshaft
    Apply a thin coat of grease to the transmission output shaft splines. Align the driveshaft to the transmission output shaft and slide it forward until fully engaged. Rotate the driveshaft to align the marks made during removal with the rear differential flange. Install the 4 driveshaft-to-differential bolts and torque to specification. Verify the driveshaft rotates freely with no binding or vibration when turned by hand.
24. 24

    Refill transmission fluid
    Locate the transmission fill plug on the side of the transmission case. Remove the fill plug. Using a fluid pump or squeeze bottle, add the manufacturer-specified transmission fluid for the T-56 transmission (verify exact Mopar spec against factory documentation) until fluid begins to drain from the fill hole. Fill until fluid begins to seep from the fill hole; verify the exact fluid capacity against factory documentation for the T-56 transmission. Install and torque the fill plug to specification. Verify the drain plug installed in step 1 is properly torqued.
    Torque spec

    Fill Plug34 Nm (25 lb-ft)

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

    Final inspection and reinstall wheels
    Perform a final inspection under the vehicle. Verify all bolts are torqued to specification, all electrical connections are secure, hydraulic lines are connected, and no tools or parts are left under the vehicle. Check for any fluid leaks. Install both rear wheels and torque lug nuts to specification in a star pattern. Lower the vehicle from jack stands.

Reassembly

1. Torque all fasteners to specification using the values provided
2. Use new flywheel bolts if originals are TTY type
3. Replace transmission drain plug washer
4. Use clutch alignment tool during pressure plate installation to ensure proper clutch disc alignment
5. Apply thread locker to flywheel bolts as specified
6. Bleed clutch hydraulic system completely to ensure proper pedal feel

Verification

• Start engine with clutch pedal depressed and verify smooth engagement when releasing pedal
• Test clutch operation in all gears, verifying smooth shifts with no grinding or resistance
• Check for proper clutch pedal height and free play adjustment
• Verify no fluid leaks from transmission, hydraulic clutch line, or bell housing area
• Test drive vehicle to verify proper clutch engagement, no slippage under load, and smooth operation
• Listen for any unusual noises from transmission or clutch during operation
• Verify reverse lights function properly
• Recheck transmission fluid level after test drive and top off if necessary

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