Pressure Plate

This procedure covers removal and replacement of the pressure plate in a 2005 Dodge Viper with the 8.3L V10 engine, requiring transmission removal to access the clutch assembly.

Warnings

Tools required

Parts

• Pressure plate assembly × 1 — Use OEM specification or high-performance equivalent
• Clutch disc × 1 — Replace with pressure plate as matched set
• Release bearing (throw-out bearing) × 1 — Recommend replacement during clutch service
• Pilot bearing × 1 — Recommend replacement during clutch service
• Transmission drain plug crush washer × 1 — If equipped

Fluids

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

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable
3. Allow exhaust system to cool completely if engine has been running
4. Raise vehicle and support securely on jack stands at all four corners
5. Remove both rear wheels for improved access and clearance
6. Position transmission jack within reach of work area

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission. Remove the transmission drain plug and allow fluid to drain completely. Reinstall drain plug with new crush washer if equipped.
   Torque spec

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

   Disconnect driveshaft
   Mark the driveshaft and differential flange for reinstallation alignment. Remove the 4 bolts securing the driveshaft to the rear differential flange. Support the driveshaft and slide it rearward out of the transmission tailshaft. Use a plastic bag and tape to cover the tailshaft opening to prevent fluid leakage and contamination.
3. 3

   Disconnect hydraulic clutch line
   Locate the hydraulic clutch line connection where it enters the transmission (the Viper uses a concentric/internal slave cylinder integrated with the release bearing). Disconnect the hydraulic line by removing the retaining clip and separating the quick-connect fitting at the transmission. Cap or plug the line to prevent fluid loss and contamination. Have shop towels ready to catch any fluid spillage.
4. 4

   Disconnect transmission electrical connections
   Disconnect the reverse light switch connector and any transmission-mounted speed/gear position sensor connectors present on this application. Note routing of wiring harnesses for reinstallation.
5. 5

   Remove exhaust system support
   Remove any exhaust hangers or brackets that may interfere with transmission removal. The exhaust system should be supported but movable to allow transmission clearance.
6. 6

   Support transmission
   Position transmission jack under the transmission pan. Secure transmission to jack with safety chain or strap. Raise jack slightly to take the weight of the transmission, but do not lift the vehicle.
7. 7

   Remove transmission crossmember
   Remove the mounting bolts securing the transmission mount to the crossmember. Remove the bolts securing the crossmember to the frame. Lower and remove the crossmember from the vehicle.
8. 8

   Remove bellhousing-to-engine bolts
   Remove all bellhousing mounting bolts. There are typically 6 bolts securing the bellhousing to the engine block. Start with upper bolts first, ensuring transmission is fully supported by jack.
9. 9

   Remove transmission
   Carefully slide the transmission straight back away from the engine, ensuring the input shaft clears the clutch disc and pilot bearing. The transmission must move rearward in a straight line to avoid damaging the clutch disc. Once the input shaft is clear, lower the transmission jack and remove transmission from under vehicle. Do not allow the transmission weight to hang on the input shaft.
10. 10

    Remove pressure plate and clutch disc
    Use a flywheel holding tool or large screwdriver wedged between flywheel teeth and bellhousing to prevent rotation. Working in a star pattern, loosen each pressure plate bolt gradually (1-2 turns at a time) to prevent warping. Remove all pressure plate bolts and carefully remove the pressure plate assembly. Support the clutch disc as you remove the pressure plate to prevent it from falling. Note the orientation of the clutch disc for reference.
    ⚠Loosen pressure plate bolts gradually in a star pattern. Uneven release of spring pressure can warp the flywheel or pressure plate.
    Torque spec

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

    Inspect flywheel and remove pilot bearing
    Inspect flywheel surface for hot spots (blue discoloration), cracks, scoring, or excessive wear. Measure flywheel thickness if resurfacing is being considered. Use a pilot bearing puller or slide hammer to remove the pilot bearing from the center of the crankshaft. Inspect the release bearing on the transmission input shaft retainer and replace if worn.
12. 12

    Install new pilot bearing
    Lightly lubricate the new pilot bearing outer diameter with high-temperature bearing grease. Install the pilot bearing into the crankshaft using a bearing driver or appropriate socket that contacts only the outer race. Drive bearing in until it is fully seated and flush with the crankshaft bore.
13. 13

    Install clutch disc and pressure plate
    Clean the flywheel surface thoroughly with brake cleaner and allow to dry. Ensure no oil or grease contacts the friction surfaces. Insert the clutch alignment tool through the clutch disc and into the pilot bearing. Position the clutch disc against the flywheel with the damper springs facing the transmission (away from flywheel). The disc will typically be marked 'Flywheel Side' on one side. Position the new pressure plate over the clutch disc, aligning the dowel pins. Install all pressure plate bolts hand-tight. Using a star pattern, tighten pressure plate bolts gradually and evenly in multiple passes until reaching final torque specification. Remove the clutch alignment tool.
    ⚠Clutch disc must be installed with correct orientation. Damper springs typically face toward transmission. Verify marking on disc hub.
    ⚠Tighten pressure plate bolts in star pattern gradually to ensure even clamping force and prevent warping.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
14. 14

    Install new release bearing
    Install the new concentric slave cylinder/release bearing assembly onto the transmission input shaft bearing retainer per the manufacturer procedure. Ensure it is properly seated and the hydraulic fitting is intact. Do not over-grease; the Viper uses a hydraulic concentric release bearing with no mechanical release fork.
15. 15

    Install transmission
    Apply a thin film of high-temperature grease to the transmission input shaft splines (avoid excess that could contaminate clutch). Position transmission on transmission jack and raise into position. Carefully align input shaft with clutch disc splines and pilot bearing. Slide transmission forward, ensuring input shaft enters the pilot bearing smoothly. If resistance is felt, do not force it. Rotate the transmission output shaft slightly while applying light forward pressure to help splines align. Once the bellhousing contacts the engine block, install all bellhousing mounting bolts and tighten to specification.
16. 16

    Install transmission crossmember and mount
    Raise transmission into position using transmission jack. Install crossmember to frame and tighten bolts. Install transmission mount to crossmember bolts and tighten to specification. Once crossmember is secure, remove transmission jack.
17. 17

    Reconnect driveshaft
    Clean driveshaft and differential flanges. Align marks made during disassembly. Install driveshaft to differential flange and install all 4 bolts. Tighten in a cross pattern to proper torque specification.
18. 18

    Reconnect electrical and hydraulic connections
    Reconnect vehicle speed sensor and reverse light switch connectors. Reconnect hydraulic clutch line to slave cylinder, ensuring quick-connect fitting is fully seated and retaining clip is installed.
19. 19

    Reinstall exhaust supports and wheels
    Reinstall any exhaust hangers or brackets removed during transmission removal. Install both rear wheels and tighten lug nuts to specification in a star pattern.
20. 20

    Refill transmission fluid
    Refill transmission with the manufacturer-specified quantity of the Mopar/T56-specified manual transmission fluid (verify exact spec and capacity for the 2005 Viper T56) through the fill plug opening. Fluid should reach the bottom of the fill plug hole. Reinstall fill plug.
21. 21

    Bleed clutch hydraulic system
    Check clutch master cylinder fluid level and top off with the manufacturer-specified brake fluid (verify DOT 3 vs DOT 4 for the 2005 Viper) if necessary. Bleed the clutch hydraulic system at the bleeder valve on the slave cylinder to remove any air introduced during service. Have an assistant pump the clutch pedal while you open the bleeder valve to release air bubbles. Repeat until fluid flows without air bubbles. Verify clutch master cylinder remains full during bleeding process.

Reassembly

1. Torque all fasteners to specifications using a star pattern where applicable
2. Ensure driveshaft alignment marks are matched during installation to prevent vibration
3. Verify clutch hydraulic system is properly bled with firm pedal feel before test driving
4. New clutch assemblies require a break-in period of 200-300 miles of moderate driving before full-load applications

Verification

• Reconnect battery and start engine to verify no warning lights or unusual noises
• With engine running and transmission in neutral, depress clutch pedal and verify smooth engagement into first and reverse gears without grinding
• Check for transmission fluid leaks around drain plug and fill plug
• Check for clutch hydraulic fluid leaks at slave cylinder connection
• Test drive vehicle to verify smooth clutch engagement and disengagement through all gears
• Verify no clutch slippage under acceleration and smooth shifting under various load conditions
• Recheck clutch pedal feel and master cylinder fluid level after test drive

Related trouble codes on this vehicle

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