Clutch Disc

Complete removal and replacement of the clutch disc on a 2008 Dodge Viper 8.4L V10, requiring transmission removal to access the clutch assembly.

Warnings

Tools required

Parts

• Clutch disc × 1 — Use OEM specification
• Clutch pressure plate (if replacing) × 1 — Use OEM specification
• Throw-out bearing (if replacing) × 1 — Use OEM specification
• Pilot bearing (if replacing) × 1 — Use OEM specification
• Transmission gasket/sealant × 1 — Use OEM specification

Fluids

• Pennzoil Synchromesh 75W-90 — 4.2 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable
3. Raise vehicle on lift or jack stands to provide adequate working clearance underneath
4. Remove exhaust system from manifolds back to allow transmission removal clearance
5. Drain transmission fluid into appropriate container
6. Remove driveshaft and mark orientation for reinstallation

Procedure

1. 1

   Support engine and remove crossmember
   Install engine support fixture or chain hoist to securely support the engine weight. Remove the transmission crossmember mounting bolts and lower the crossmember. There are typically 4 bolts securing the crossmember to the frame rails.
2. 2

   Disconnect transmission electrical and mechanical connections
   Disconnect the reverse light switch electrical connector, any transmission-mounted sensor connectors (verify against the wiring diagram), and clutch slave cylinder hydraulic line. Remove the slave cylinder mounting bolts and secure the cylinder out of the way without letting it hang on the hydraulic line. Disconnect the shifter linkage at the transmission.
3. 3

   Remove bellhousing-to-engine bolts
   Remove the bellhousing dust cover if equipped. Remove the bellhousing-to-engine block mounting bolts. The bellhousing is secured to the engine block by multiple bolts around the perimeter (verify exact count against the FSM before removal). Note the location of any ground straps or wiring brackets attached to these bolts.
4. 4

   Remove transmission
   Position transmission jack under transmission and secure with safety chain or strap. Slightly raise transmission to take weight off mounts. Remove any remaining transmission mount bolts. Carefully slide transmission rearward away from engine, keeping it level to prevent input shaft damage. Once input shaft clears bellhousing, lower transmission and remove from under vehicle.
5. 5

   Inspect clutch components
   Examine the pressure plate fingers for even wear, the flywheel surface for heat checking or scoring, and the throw-out bearing for noise or roughness. Check the pilot bearing in the crankshaft for wear. Document condition to determine which components require replacement.
6. 6

   Remove pressure plate
   Install flywheel holding tool to prevent rotation. Mark the pressure plate orientation to the flywheel with paint or punch marks for reinstallation balance reference. Gradually loosen the pressure plate-to-flywheel bolts in a criss-cross pattern (verify exact bolt count against the FSM), turning each bolt 1-2 turns at a time to prevent warping. Remove bolts, pressure plate, and clutch disc.
7. 7

   Replace pilot bearing (if necessary)
   If pilot bearing shows wear, remove it using a slide hammer with internal puller attachment or pack the bearing cavity with grease and use a close-fitting shaft to hydraulically force it out. Install new pilot bearing using appropriate driver, ensuring it is seated fully and squarely in the crankshaft.
8. 8

   Clean and inspect flywheel
   Clean flywheel surface with brake cleaner and inspect for cracks, hot spots, or excessive scoring. If flywheel requires resurfacing, remove it following manufacturer procedures. Minimum thickness specifications must be maintained. Clean all fastener threads with wire brush.
9. 9

   Install new clutch disc and pressure plate
   Wipe flywheel surface with clean, lint-free cloth. Install new clutch disc against flywheel oriented per the disc markings — the side marked 'flywheel side' faces the flywheel and the side marked 'pressure plate side' (typically the raised damper spring hub) faces the pressure plate. Insert clutch alignment tool through disc hub into pilot bearing to center the disc. Position pressure plate over disc, aligning marks made during removal if reusing the same plate. Install pressure plate bolts finger-tight.
10. 10

    Torque pressure plate bolts
    Tighten the pressure plate bolts gradually in a criss-cross pattern in three stages, working up to the final OEM torque specification (verify count and torque against the FSM before assembly). This ensures even clamping force and prevents warping. Keep the alignment tool in place throughout this process.
11. 11

    Prepare transmission for installation
    Install new throw-out bearing on clutch fork if replacing. Apply a thin coat of high-temperature bearing grease to the input shaft splines (avoid getting grease on clutch disc). Verify clutch alignment tool is still centered in pilot bearing. Clean bellhousing mating surface and apply sealant or install new gasket as specified.
12. 12

    Install transmission
    Position transmission on transmission jack and raise into position. Align input shaft with clutch disc hub, using alignment tool as guide. Slowly slide transmission forward, rotating input shaft slightly if needed to engage splines. Once transmission is within 1 inch of bellhousing, the input shaft should slide freely through the clutch disc. Do not force it or use bellhousing bolts to draw the transmission in. Remove alignment tool only after input shaft is fully seated. Install bellhousing-to-engine bolts and tighten in a star pattern to the OEM torque specification (verify against the FSM).
13. 13

    Reconnect mounts and crossmember
    Raise transmission into alignment with mounts. Install transmission mount bolts and tighten. Position crossmember and install mounting bolts, tightening to the OEM torque specification (verify against the FSM). Remove engine support fixture.
14. 14

    Reconnect all components
    Install clutch slave cylinder and tighten mounting bolts. Reconnect hydraulic line and bleed clutch system if necessary. Reconnect all electrical connectors including reverse light switch and speed sensor. Reconnect shifter linkage and adjust as needed. Install driveshaft, aligning marks made during removal. Install exhaust system with new gaskets as needed.
15. 15

    Refill transmission and final checks
    Refill transmission with the OEM-specified quantity and fluid type for the T56 (verify exact capacity and fluid specification against the FSM). Reconnect negative battery cable. Lower vehicle. Start engine and verify clutch pedal feel and operation. Test shift through all gears with engine running. Check for leaks around slave cylinder and transmission seals.

Reassembly

1. Torque all fasteners to specification in the proper sequence
2. Bleed clutch hydraulic system if line was disconnected
3. Verify driveshaft is installed with alignment marks matched
4. Ensure all electrical connectors are fully seated and locked

Verification

• Start engine and verify smooth clutch engagement without shudder or slippage
• Test shift quality through all gears with engine running and vehicle stationary
• Road test vehicle to verify smooth engagement under load and proper clutch release
• Check for transmission fluid leaks after test drive
• Verify clutch pedal free play is within specification (approximately 1 inch)
• Confirm no abnormal noises from clutch or transmission during operation

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