Throw-Out Bearing

Replace the throw-out bearing (clutch release bearing) on a 2005 Dodge Viper with 8.3L V10 engine, requiring transmission removal to access the clutch assembly.

Warnings

Tools required

Parts

• Throw-out bearing (clutch release bearing) × 1 — Use OEM specification
• Clutch kit (pressure plate, disc, and bearing) × 1 — Consider full replacement while transmission is removed
• Transmission input shaft seal × 1 — Inspect and replace if leaking
• Pilot bearing × 1 — Inspect and replace if worn
• Flywheel bolts × 6 — TTY bolts - replace if reusing is not recommended by OEM
• Transmission drain plug crush washer × 1 — If equipped

Fluids

• 75W-90 synthetic GL-4 — 4 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Allow exhaust system to cool completely if vehicle was recently operated
4. Raise front and rear of vehicle on jack stands at proper lift points, ensuring adequate clearance for transmission removal (minimum 24 inches recommended)
5. Remove rear wheels to access exhaust hangers if needed
6. Place transmission jack under transmission and adjust for proper support height

Procedure

1. 1

   Drain transmission fluid
   Position drain pan under transmission. Remove the drain plug from the transmission case and allow fluid to drain completely. Inspect fluid for metal particles or unusual debris indicating internal wear. Reinstall drain plug with new crush washer if equipped.
   Torque spec

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

   Remove exhaust components
   Disconnect exhaust system at the collector or mid-pipe connection to provide clearance for transmission removal. Support exhaust with mechanics wire or remove hangers as needed. On the Viper, the side-exit exhaust requires disconnection at the headers or mid-pipe depending on configuration. Remove 4 bolts at each collector flange and carefully lower exhaust sections away from transmission bellhousing area.
3. 3

   Disconnect driveshaft
   Mark alignment of driveshaft to differential flange for proper reinstallation. Remove the 4 bolts securing the driveshaft universal joint to the rear differential flange. Carefully slide driveshaft rearward to disengage from transmission output shaft. Support and remove driveshaft from vehicle. Install a plug or plastic bag over transmission output to prevent fluid leakage.
   ℹ️Mark driveshaft orientation with paint or marker to maintain balance during reinstallation.
4. 4

   Disconnect clutch hydraulic line
   Locate the clutch slave cylinder on the transmission bellhousing. The Viper uses an external slave cylinder that operates the clutch release fork. Disconnect the hydraulic line at the fitting on the bellhousing by removing the retaining clip and pulling the quick-disconnect fitting. Have a rag ready to catch any fluid spillage. Cap or plug the line to prevent fluid loss and contamination.
5. 5

   Disconnect electrical connections and shifter
   Disconnect the reverse light switch connector on the transmission. Disconnect the vehicle speed sensor (VSS) if equipped. Remove the shifter by unbolting the 4 mounting bolts securing the shifter assembly to the transmission top cover. Lift shifter assembly straight up and out. Cover the opening with a rag to prevent debris entry.
6. 6

   Remove transmission mount and crossmember
   Support transmission weight with transmission jack positioned at the pan rails. Remove the 2 bolts securing the transmission mount to the crossmember. Remove the 4 bolts securing the crossmember to the frame rails. Carefully lower and remove the crossmember from the vehicle.
7. 7

   Remove bellhousing bolts
   Remove all bellhousing-to-engine block mounting bolts. On the Viper 8.3L V10 with Tremec T56 transmission, there are 6 bellhousing bolts around the perimeter. Start with the upper bolts and work your way around. Note the location of any different-length bolts or brackets. The top bolts may require extensions or universal joints to access.
   ⚠Ensure transmission jack is properly supporting full weight before removing final bolts.
8. 8

   Remove transmission
   With all bolts removed and transmission securely supported on jack, carefully slide transmission straight back away from engine. Keep transmission level to avoid binding the input shaft in the clutch disc splines. Move slowly and watch for any remaining connections or obstructions. Once the input shaft clears the clutch assembly, lower transmission on jack and remove from under vehicle. Do not allow weight to hang on input shaft during removal.
9. 9

   Inspect and remove throw-out bearing
   With transmission removed, inspect the throw-out bearing (release bearing) on the front of the transmission input shaft retainer. The bearing slides on the input shaft sleeve and is retained by the clutch fork or hydraulic actuator. On the Viper's external slave cylinder design, the throw-out bearing is a separate component held to the release fork. Disengage the bearing from the release fork and slide the old throw-out bearing off the input shaft retainer sleeve. Inspect the input shaft sleeve for wear, grooves, or discoloration.
   ℹ️If bearing shows any roughness, noise when spun, or discoloration, replacement is mandatory. This is not a wear item to reuse.
10. 10

    Inspect clutch components
    Inspect the pressure plate fingers for even wear, the clutch disc for remaining material thickness (minimum 0.020 inch above rivet heads), and the flywheel surface for heat checking, cracks, or grooves. Inspect pilot bearing in the crankshaft for roughness or noise. Check pressure plate bolts for tightness. If any component shows excessive wear or the clutch has over 50,000 miles, consider full clutch replacement while transmission is removed.
11. 11

    Install new throw-out bearing
    Clean the transmission input shaft sleeve with solvent and inspect for wear. Lightly lubricate the input shaft sleeve with high-temperature bearing grease (avoid getting grease on clutch disc area). Slide the new throw-out bearing assembly onto the input shaft sleeve, ensuring proper orientation. The bearing should slide smoothly and sit flush against its retaining surface. Secure the bearing to the clutch release fork with the fork retaining clips. Verify bearing moves freely on the sleeve and has no binding.
12. 12

    Install transmission
    Apply a small amount of high-temperature grease to the input shaft splines (very thin coat). Position transmission on jack and raise into position behind engine. Align input shaft with clutch disc splines using a clutch alignment tool if disc was removed, or by rotating output shaft to align splines. Carefully slide transmission forward, keeping it level. The input shaft must pass through the clutch disc and into the pilot bearing. Do not force - if binding occurs, check alignment. Once bellhousing contacts engine block evenly, install all 6 bellhousing bolts finger-tight, then torque in a star pattern.
    ⚠Never use bellhousing bolts to draw transmission into place. Input shaft must slide freely into clutch disc and pilot bearing.
13. 13

    Install crossmember and mount
    Raise transmission slightly with jack to align with crossmember mounting points. Install crossmember onto frame rail mounting points and install the 4 frame bolts finger-tight. Install the 2 transmission mount-to-crossmember bolts finger-tight. Torque all crossmember and mount fasteners to specification once everything is aligned.
14. 14

    Reconnect shifter and electrical connections
    Install shifter assembly onto transmission top cover, aligning the shift rod with the internal shift forks. Install 4 shifter mounting bolts and torque to specification. Reconnect the reverse light switch connector and vehicle speed sensor connector. Verify all connectors are fully seated and locked.
15. 15

    Reconnect clutch hydraulic line and driveshaft
    Reconnect the clutch hydraulic quick-disconnect fitting to the bellhousing slave cylinder port. Ensure retaining clip fully engages to prevent disconnection. Install driveshaft, aligning the marks made during removal. Install the 4 universal joint bolts at the differential flange and torque to specification. Verify driveshaft rotates freely without binding.
16. 16

    Reinstall exhaust components
    Raise exhaust system into position and reconnect at collector flanges. Install new gaskets if old ones are damaged. Torque exhaust flange bolts to specification. Reconnect or install exhaust hangers. Verify exhaust has adequate clearance from transmission, driveshaft, and frame components.
17. 17

    Refill transmission
    Using a fluid pump, refill transmission through the fill plug opening on the side of the case with 4.0 quarts of 75W-90 synthetic GL-4 rated manual transmission fluid. Fill until fluid begins to drip from fill hole. Install fill plug and torque to specification. Verify drain plug is tight.
    ⚠Use only GL-4 rated fluid. GL-5 fluid contains additives that will damage the brass synchronizers in the Tremec T56 transmission.

Reassembly

1. Reinstall rear wheels and torque lug nuts to specification in star pattern
2. Remove jack stands and carefully lower vehicle to ground
3. Reconnect negative battery cable
4. Bleed clutch hydraulic system if air entered the line during disconnection

Verification

• Start engine and verify no unusual noises from bellhousing area
• With engine running, depress clutch pedal and verify smooth engagement with no binding or unusual sounds
• Shift through all gears with engine off to verify proper shifter operation
• With engine running, shift through all gears verifying smooth clutch engagement and disengagement
• Test drive vehicle and verify clutch engages smoothly without slipping, chattering, or noise
• Verify no fluid leaks from transmission drain plug, fill plug, or hydraulic line connections
• Check transmission fluid level after test drive and top off if needed
• Verify driveshaft does not vibrate at highway speeds (indicates proper alignment)

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