Dual Mass Flywheel

Complete removal and replacement of the dual mass flywheel on a 2005 Dodge Viper 8.3L V10, requiring transmission removal, clutch disassembly, and flywheel replacement with precise torque specifications.

Warnings

Tools required

Parts

• Dual mass flywheel × 1 — Use OEM specification
• Clutch disc × 1 — Replace with flywheel per OEM recommendation
• Pressure plate × 1 — Replace with flywheel per OEM recommendation
• Pilot bearing × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — If equipped
• Flywheel bolts × 1 — Use new if TTY type specified by OEM

Fluids

• 75W-90 synthetic GL-4 manual transmission fluid — 4 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Allow engine and exhaust system to cool completely if recently operated
4. Raise vehicle and support securely on jack stands at all four corners
5. Remove rear wheels to improve access if needed
6. Install engine support fixture or secure engine hoist to support engine weight during transmission removal

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission. Remove transmission drain plug and allow fluid to drain completely. Inspect drain plug washer and replace if damaged or equipped with crush washer. Reinstall drain plug finger-tight for now to prevent debris entry.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Remove exhaust components
   Disconnect exhaust system from manifolds and support or remove exhaust components as necessary to provide clearance for transmission removal. On the Viper, disconnect the exhaust as necessary to provide clearance for transmission removal per OEM routing (verify disconnection points against OEM documentation). Support exhaust with wire or remove completely if clearance is insufficient.
3. 3

   Disconnect driveshaft
   Mark driveshaft-to-differential flange orientation for reinstallation alignment. Remove the driveshaft flange bolts at the rear differential (verify exact count against OEM documentation). Support driveshaft and slide forward to disengage from differential output shaft. Lower driveshaft and remove from vehicle. Inspect U-joints for wear while removed.
4. 4

   Disconnect shift linkage and electrical connections
   Disconnect shift linkage from transmission shift tower. Remove shift linkage mounting hardware and position linkage aside. Disconnect reverse light switch connector and vehicle speed sensor connector from transmission case. Label connections if necessary for reinstallation.
5. 5

   Disconnect clutch hydraulic line
   Locate the clutch hydraulic line connection at the bellhousing. If equipped with an internal concentric slave cylinder (CSC), disconnect the hydraulic line at the bellhousing fitting; the CSC is located inside the bellhousing around the input shaft and comes off with the transmission. Cap or plug the line to prevent fluid loss and contamination. Verify slave cylinder type and service procedure against OEM documentation.
6. 6

   Support transmission and remove crossmember
   Position transmission jack under transmission and secure with chains or straps. Raise jack slightly to take weight off crossmember. Remove transmission crossmember mounting bolts (typically 4 bolts to frame). Lower transmission jack slightly and remove crossmember from vehicle.
7. 7

   Remove bellhousing-to-engine bolts
   Locate and remove all bellhousing-to-engine block bolts. The transmission is secured to the engine block by several bellhousing bolts. Verify the exact bolt count and torque against OEM documentation before removal. Remove bolts in a crisscross pattern to avoid warping the bellhousing. Note bolt locations as some may be different lengths. Remove bolts in a crisscross pattern to avoid warping the bellhousing. Note bolt locations as some may be different lengths.
8. 8

   Remove transmission
   With transmission supported on jack, carefully slide transmission rearward to disengage input shaft from clutch disc and pilot bearing. Move slowly and keep transmission level to prevent input shaft from hanging on clutch disc. Once input shaft clears bellhousing, lower transmission and remove from under vehicle. Handle with care due to weight.
   ⚠Keep transmission aligned with engine to prevent input shaft damage. Do not allow transmission to tilt or hang on clutch assembly.
9. 9

   Remove pressure plate and clutch disc
   Insert clutch alignment tool through clutch disc to prevent it from falling when pressure plate is removed. Mark pressure plate-to-flywheel orientation if reusing. Loosen pressure plate bolts gradually in a crisscross pattern to release spring tension evenly. Remove pressure plate bolts completely and remove pressure plate and clutch disc together. Inspect components for wear, hot spots, or damage.
10. 10

    Remove flywheel
    Install flywheel holding tool to prevent crankshaft rotation, or wedge a large pry bar between flywheel teeth and bellhousing. Remove all flywheel mounting bolts in a crisscross pattern. Verify the exact flywheel bolt count against OEM documentation for the 8.3L V10 before removal. Once all bolts are removed, carefully remove flywheel from crankshaft. Note dowel pin position if equipped. Clean crankshaft flange with wire brush and inspect for damage or runout.
    Torque spec

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

    Remove and replace pilot bearing
    Using a pilot bearing puller or slide hammer with internal jaw attachment, remove pilot bearing from center of crankshaft. Inspect crankshaft pilot bore for damage. Install new pilot bearing using appropriate driver or socket slightly smaller than bearing outer diameter. Drive bearing in until flush with crankshaft face or to specified depth. Lubricate bearing lightly with high-temp grease.
12. 12

    Install new dual mass flywheel
    Clean crankshaft flange thoroughly and ensure it is free of oil. Align new dual mass flywheel with dowel pin(s) on crankshaft and install onto crankshaft flange. Install new flywheel bolts (if TTY type) or cleaned original bolts hand-tight. Using flywheel holding tool, torque flywheel bolts in a star pattern to specification. Follow any additional torque angle requirements if specified by flywheel manufacturer.
    ⚠Verify flywheel bolt type (TTY vs reusable) before installation. Using old TTY bolts can result in bolt failure and catastrophic engine damage.
    Torque spec

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

    Install new clutch disc and pressure plate
    Insert clutch alignment tool through new clutch disc and into pilot bearing. Position clutch disc on flywheel with disc hub facing transmission (damper springs toward transmission). Place new pressure plate over clutch disc, aligning with original marks if reusing, or distributing mounting holes evenly if new. Install pressure plate bolts hand-tight. Tighten pressure plate bolts gradually in a crisscross pattern to allow even seating. Torque pressure plate bolts to specification. Leave clutch alignment tool in place until transmission is reinstalled.
14. 14

    Reinstall transmission
    Apply light coating of high-temp grease to transmission input shaft splines. Position transmission on transmission jack and raise into position. Carefully guide input shaft through clutch disc using alignment tool as guide. Align transmission with engine block and slide forward. Remove clutch alignment tool once input shaft is partially engaged. Continue sliding transmission forward until bellhousing contacts engine block evenly. Install bellhousing-to-engine bolts and tighten in a crisscross pattern to specification.
15. 15

    Reinstall crossmember and complete reassembly
    Raise transmission slightly with jack and install transmission crossmember. Install crossmember mounting bolts and torque to specification. Remove transmission jack. Reconnect clutch hydraulic line to slave cylinder. Reconnect shift linkage to transmission shift tower and secure all mounting hardware. Reconnect reverse light switch and vehicle speed sensor connectors. Reinstall driveshaft, aligning marks made during removal, and torque flange bolts to specification. Reinstall exhaust components and secure all connections. Torque transmission drain plug to specification with new crush washer if equipped.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)
16. 16

    Refill transmission and bleed clutch
    Remove transmission fill plug. Using fluid pump or squeeze bottle, refill transmission with the OEM-specified manual transmission fluid type and quantity (verify both against OEM documentation) through fill hole until fluid reaches bottom of fill hole. Reinstall fill plug and torque to specification. Bleed clutch hydraulic system according to manufacturer procedure if hydraulic line was disconnected. Pump clutch pedal several times and verify smooth operation with proper engagement point.

Reassembly

1. Reinstall rear wheels if removed and torque lug nuts to specification
2. Lower vehicle from jack stands
3. Reconnect negative battery cable
4. Start engine and verify no abnormal noises from flywheel or clutch area
5. Test clutch engagement with engine running and verify smooth operation through all gears
6. Check for fluid leaks around transmission drain plug and fill plug after initial test drive

Verification

• Start engine and listen for smooth operation with no rattling or unusual vibration from flywheel area
• Verify clutch pedal feel is consistent and engagement point is appropriate
• Test shift quality through all gears with engine running and clutch depressed
• Perform short test drive and verify smooth clutch engagement and no driveline vibration
• Check transmission fluid level after test drive and top off if necessary
• Verify no fluid leaks from transmission drain plug, fill plug, or clutch hydraulic connections
• Confirm proper clutch disengagement by attempting to shift into reverse with engine running

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