Clutch Kit

Complete clutch kit replacement for 2005 Dodge Viper 8.3L V10, including transmission removal, clutch disc, pressure plate, and release bearing installation.

Warnings

Tools required

Parts

• Clutch kit (disc, pressure plate, release bearing) × 1 — Use OEM specification or performance equivalent
• Pilot bearing × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Clutch fork boot × 1 — Use OEM specification
• Transmission drain plug crush washer (if equipped) × 1 — Use OEM specification
• Bell housing bolts (inspect and replace if damaged) × 1 — Use OEM specification
• Engine oil and filter × 1 — Use OEM specification

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 and secure away from terminal.
3. Allow exhaust system to cool completely (minimum 2 hours after last operation).
4. Raise vehicle to working height and support on jack stands at manufacturer-specified lift points.
5. Remove both rear wheels for access and weight reduction.
6. Place drain pan under transmission and drain manual transmission fluid completely via drain plug.
7. Gather all tools and parts before beginning to minimize time with vehicle disassembled.

Procedure

1. 1

   Remove exhaust system components
   Disconnect exhaust system from manifolds at collector flanges. Remove exhaust hangers and lower exhaust system enough to provide clearance for transmission removal. On the Viper, the side exhaust routing requires complete removal of the side sill exhaust sections. Support exhaust components with jack stands or suspend with wire to prevent damage.
2. 2

   Disconnect driveshaft
   Mark driveshaft-to-differential flange relationship with paint or punch marks for proper reinstallation alignment. Remove the driveshaft flange bolts at the rear differential (verify exact count against the 2005 Viper FSM). Remove the driveshaft-to-transmission fasteners (verify connection type and bolt count against the 2005 Viper FSM), then remove the driveshaft from the vehicle. Confirm whether the driveshaft uses a slip-yoke or a bolted flange at the transmission end before proceeding. Support driveshaft and remove from vehicle. Plug transmission output shaft opening with clean shop rag to prevent fluid loss and contamination.
3. 3

   Disconnect shifter and hydraulic clutch line
   Working from inside vehicle, remove shifter boot and disconnect shifter mechanism from transmission shifter tower. Remove the fasteners securing the shifter assembly (typically 4 bolts through the transmission tunnel). From underneath vehicle, disconnect hydraulic clutch line from clutch slave cylinder at bell housing. Use flare nut wrench to prevent line damage. Cap or plug line to minimize fluid loss. Secure clutch line away from transmission removal path.
4. 4

   Support engine and remove crossmember
   Install engine support bar across engine bay or attach hoist to engine lift points to support engine weight. Place transmission jack under transmission pan with wooden block to distribute load. Remove rear transmission mount fasteners. Remove transmission crossmember mounting bolts and lower crossmember from vehicle. Verify engine is securely supported before proceeding.
5. 5

   Disconnect electrical connections
   Disconnect all electrical connectors from transmission including reverse light switch, vehicle speed sensor (if equipped), and any other harness connections. Release any wire harness clips securing harness to transmission or bell housing. Secure harnesses away from transmission removal path.
6. 6

   Remove bell housing and transmission mounting bolts
   Remove all bell housing-to-engine block bolts. The Viper T56 transmission bell housing bolt count must be verified against the 2005 Viper FSM before removal; remove all bell housing-to-engine block bolts around the bell housing perimeter. Start with upper bolts working down to lower bolts. Support transmission weight with transmission jack throughout this process. Verify all fasteners are removed before attempting to separate transmission.
   Torque spec

   Bell Housing Bolts47 Nm (35 lb-ft)
7. 7

   Remove transmission assembly
   With assistant steadying transmission, carefully slide transmission rearward away from engine. Keep transmission input shaft aligned with clutch disc and pilot bearing to avoid damaging clutch disc. Once input shaft clears clutch assembly, angle transmission downward at front and guide rearward and down from vehicle. The large Viper V10 and frame rails create tight clearances; patience and small adjustments are required. Lower transmission onto shop floor using transmission jack.
8. 8

   Inspect and remove clutch fork and release bearing
   Remove clutch release bearing from transmission input shaft bearing retainer. Inspect release bearing for noise, roughness, or binding (replace as part of clutch kit). Disengage clutch fork from bell housing pivot ball by prying fork away from ball. Remove fork boot and inspect fork for wear at bearing contact point and pivot ball socket. Replace fork if worn or cracked.
9. 9

   Remove pressure plate and clutch disc
   Insert clutch alignment tool through clutch disc hub to support disc and prevent dropping when pressure plate is removed. Mark pressure plate-to-flywheel orientation if reusing (not applicable with new clutch kit). Loosen pressure plate bolts in star pattern, 2-3 turns at a time to gradually release spring tension and prevent warping. Verify the pressure plate bolt count against the 2005 Viper FSM before removal; loosen all pressure plate bolts securing the assembly. Once all bolts are loose, remove bolts completely. Remove pressure plate and clutch disc together, keeping alignment tool in place until disc is clear of flywheel.
   Torque spec

   Pressure Plate Bolts27 Nm (20 lb-ft)
10. 10

    Inspect flywheel and replace pilot bearing
    Inspect flywheel surface for heat checking (fine cracks), hot spots (discoloration), scoring, or excessive wear. Check flywheel runout with dial indicator if available; maximum runout is typically 0.005 inch. Minor glazing can be cleaned with emery cloth; significant damage requires resurfacing or replacement (adds time to procedure). Remove pilot bearing from center of crankshaft using slide hammer with internal puller attachment. Clean pilot bearing bore in crankshaft thoroughly. Install new pilot bearing using appropriately sized driver or old input shaft, seating bearing flush with crankshaft face. Ensure bearing is fully seated and square.
11. 11

    Clean and prepare mating surfaces
    Clean flywheel face with parts cleaning solvent to remove all oil, grease, and residue. Wipe dry with clean, lint-free cloth. Inspect flywheel bolts if visible; Viper flywheel bolts may be TTY (torque-to-yield) and should be replaced if removed. Clean pressure plate mounting surface. Inspect bell housing for cracks or damage. Clean transmission input shaft splines with solvent and wire brush, then wipe clean and dry. Do not apply solvent or leave residue on the input shaft splines; they will receive a very light coat of high-temperature clutch grease during reassembly.
12. 12

    Install new clutch disc and pressure plate
    Apply small amount of high-temperature clutch grease to input shaft splines on transmission (very light coat only). Place new clutch disc on flywheel with friction material facing flywheel and damper springs facing transmission (stamped side typically reads 'Flywheel Side' or 'Pressure Plate Side'). Insert clutch alignment tool through disc hub and into pilot bearing to center disc. Place new pressure plate over clutch disc, aligning dowel pins or marks. Start all pressure plate bolts by hand. Tighten pressure plate bolts gradually in star pattern to final torque specification, working in 3-4 stages to ensure even clamping and prevent disc distortion. Verify clutch disc moves freely on alignment tool after pressure plate is fully torqued.
    Torque spec

    Pressure Plate Bolts27 Nm (20 lb-ft)
13. 13

    Install release bearing and clutch fork
    Apply small amount of high-temperature grease to bell housing pivot ball. Install clutch fork onto pivot ball, ensuring fork is fully seated. Install new fork boot onto bell housing. Install new release bearing onto transmission input shaft bearing retainer, ensuring bearing clips engage properly. Apply light coat of high-temperature grease to clutch fork fingers where they contact release bearing. Verify fork moves smoothly and bearing is secure.
14. 14

    Install transmission assembly
    Inspect transmission input shaft seal and replace if leaking or damaged. Position transmission on transmission jack and raise to approximate installation height. Apply very light coat of high-temperature grease to transmission input shaft splines if not already done. With assistant guiding, carefully align transmission input shaft with clutch disc splines and pilot bearing. Rotate transmission output shaft by hand to help align splines. Slide transmission forward, keeping input shaft centered. Do NOT force transmission; if resistance is felt, pull back slightly and re-align. Continue until bell housing is flush with engine block. Resistance in the last inch indicates misalignment.
15. 15

    Install bell housing bolts and reconnect transmission
    Install all bell housing-to-engine block bolts and tighten in star pattern to specification. Raise transmission into final position and install transmission crossmember. Torque crossmember mounting bolts to specification. Install rear transmission mount fasteners and torque to specification. Remove transmission jack and engine support. Reconnect all electrical connectors to transmission. Reconnect hydraulic clutch line to slave cylinder using new sealing washers if equipped; torque fitting properly to avoid leaks. Reconnect shifter mechanism and secure shifter assembly fasteners.
    Torque spec

    Bell Housing Bolts47 Nm (35 lb-ft)
16. 16

    Install driveshaft and exhaust
    Remove plug from transmission output shaft. Align driveshaft with marks made during removal and install into transmission output shaft. Install driveshaft flange bolts at differential and torque to specification. Verify driveshaft rotates freely by turning output flange by hand. Reinstall exhaust system components, aligning to original positions and securing all hangers. Torque exhaust flange bolts to specification.
17. 17

    Refill transmission and bleed clutch system
    Refill manual transmission with the manufacturer-specified fluid and capacity through the fill plug opening (verify exact fluid type and capacity against the 2005 Viper FSM — the T56 typically requires a specific Mopar manual transmission fluid rather than a generic 75W-90 GL-4 gear oil). Install and torque the fill plug and drain plug to the manufacturer-specified values, using new crush washers if equipped. Bleed hydraulic clutch system: have assistant pump clutch pedal 10-15 times and hold pedal to floor. Open bleeder valve on slave cylinder until fluid flows without air bubbles, then close bleeder. Repeat until pedal feels firm and no air is present in system. Check clutch master cylinder reservoir level and top off with DOT 4 brake fluid as needed.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)
18. 18

    Final inspection and test
    Install rear wheels and torque lug nuts to specification. Reconnect negative battery cable. Lower vehicle to ground. Start engine and verify no unusual noises from clutch or transmission area. Check for fluid leaks at transmission, clutch hydraulic line, and driveshaft. With engine running and transmission in neutral, depress clutch pedal fully and shift through all gears to verify smooth engagement. Test drive vehicle in safe area to verify clutch engagement point, smooth shifts, and no slippage under acceleration. Re-check all fluid levels after test drive.

Reassembly

1. Torque all fasteners to specified values using proper tightening sequences.
2. Ensure clutch disc is installed with correct orientation (damper springs toward transmission).
3. Use new crush washers on hydraulic fittings and drain plugs where applicable.
4. Bleed clutch hydraulic system thoroughly to remove all air from system.
5. Verify driveshaft alignment marks match during reinstallation to maintain driveline balance.
6. Check all electrical connectors are fully seated and secured.
7. Verify shifter operates smoothly through all gears before final test drive.

Verification

• Clutch pedal feel is firm with normal resistance and returns fully when released.
• Clutch engages smoothly without chatter, grabbing, or slipping.
• All gears engage smoothly without grinding or resistance when clutch is fully depressed.
• No fluid leaks present at transmission, clutch hydraulic line connections, or driveshaft.
• No unusual noises from clutch, transmission, or driveline during operation.
• Test drive confirms smooth acceleration without clutch slip under full throttle.
• Transmission shifts smoothly through all gears under various driving conditions.
• Clutch disengages fully with no gear clash when shifting.
• Pedal engagement point is appropriate (typically mid-pedal travel).

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