Dual Mass Flywheel

This procedure covers removal and replacement of the dual mass flywheel on a 2008 Dodge Viper with 8.4L V10 engine, requiring transmission and clutch removal.

Warnings

Tools required

Parts

• Dual mass flywheel assembly × 1 — Use OEM specification
• Clutch disc × 1 — Use OEM specification or performance replacement
• Pressure plate × 1 — Use OEM specification or performance replacement
• Pilot bearing × 1 — Use OEM specification
• Flywheel bolts × 8 — Use new OEM bolts
• Pressure plate bolts × 6 — Use new OEM bolts

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 securely support on jack stands at all four corners at proper lift points.
4. Remove the exhaust system from catalytic converters back to allow clearance for transmission removal.
5. Drain transmission fluid into catch pan by removing drain plug from bottom of transmission case.
6. Install engine support fixture or secure engine hoist to prevent engine from shifting when transmission mounts are removed.

Procedure

1. 1

   Remove driveshaft
   Mark the driveshaft-to-differential flange orientation for proper reinstallation. Remove the 4 bolts securing the driveshaft to the rear differential companion flange. Support the driveshaft and slide it rearward to disengage from the transmission output shaft. Remove the driveshaft from under the vehicle.
2. 2

   Disconnect shift linkage and slave cylinder
   Disconnect the hydraulic clutch line at the slave cylinder quick-disconnect fitting. Position the line out of the way. Remove the 2 bolts securing the hydraulic slave cylinder to the transmission bellhousing and secure the slave cylinder out of the way without disconnecting the line from the cylinder. Disconnect the shift linkage at the transmission by removing the retaining clips and lifting the linkage rods off the shift arms. Note: If the hydraulic clutch line is opened, the system may require bleeding per the service manual. Cap the line to prevent contamination if completely disconnected.
   ℹ️The hydraulic clutch system is self-bleeding on the Viper. Cap the line to prevent contamination if completely disconnected.
3. 3

   Disconnect electrical connectors and starter
   Disconnect the reverse light switch connector and any transmission-mounted electrical connectors (verify presence and type of speed sensor against the 2008 Viper service manual). Remove the 2 bolts securing the starter motor to the bellhousing. Disconnect the starter wiring (battery cable and solenoid wire) and remove the starter motor from the vehicle.
4. 4

   Support and remove transmission crossmember
   Position transmission jack under the transmission and secure with safety chains. Raise jack slightly to take weight off the crossmember. Remove the 4 bolts securing the transmission mount to the crossmember. Remove the 2 bolts on each side (4 total) securing the crossmember to the frame rails. Lower and remove the crossmember from the vehicle.
5. 5

   Remove bellhousing bolts
   Remove all bellhousing-to-engine block bolts. There are 6 bolts securing the transmission bellhousing to the engine block around the perimeter of the bellhousing. Note bolt locations as some may be different lengths. Remove the inspection cover from the bottom of the bellhousing if present.
   ⚠Ensure the transmission is properly supported on the transmission jack before removing the final bellhousing bolts.
6. 6

   Remove transmission
   With the transmission securely supported on the jack, carefully slide the transmission straight back away from the engine. Ensure the input shaft clears the clutch disc and pilot bearing without binding. Once the input shaft is clear of the clutch, lower the transmission jack and roll the transmission out from under the vehicle. Use caution as the transmission weighs approximately 130 lbs.
7. 7

   Remove pressure plate and clutch disc
   Insert clutch alignment tool through the clutch disc to support it. Remove the 6 pressure plate bolts in a crisscross pattern, loosening each bolt gradually (1-2 turns at a time) to release spring pressure evenly. Remove the pressure plate and clutch disc assembly. Inspect components for wear or damage.
   ⚠Loosen pressure plate bolts gradually in a crisscross pattern to prevent warping the pressure plate.
8. 8

   Lock flywheel and remove flywheel bolts
   Install flywheel holding tool to lock the flywheel in position, or use a large pry bar wedged against the ring gear and a solid frame member. Remove the 8 flywheel mounting bolts. These are torque-to-yield bolts and must be discarded and replaced with new bolts during reassembly.
9. 9

   Remove dual mass flywheel
   Carefully remove the dual mass flywheel from the crankshaft flange. The flywheel weighs approximately 50 lbs and may require assistance to safely remove without dropping. Place the flywheel on a clean work surface and inspect for excessive wear, cracks, or heat damage. Inspect the crankshaft flange for damage or wear.
10. 10

    Remove and replace pilot bearing
    Remove the pilot bearing from the center of the crankshaft using a pilot bearing puller or slide hammer. Clean the pilot bearing bore in the crankshaft thoroughly. Install the new pilot bearing using a pilot bearing installation tool or appropriately sized socket, driving it in squarely until it is flush with the crankshaft bore.
11. 11

    Prepare crankshaft flange and install new flywheel
    Clean the crankshaft flange and flywheel mounting surface thoroughly with brake cleaner. Remove any old thread locker from crankshaft bolt holes using a wire brush or thread chaser. Align the new dual mass flywheel to the crankshaft flange, ensuring proper indexing (flywheel will only fit one way due to offset bolt pattern). Install new flywheel bolts, applying thread locker only if specified by the factory service procedure for these torque-to-yield bolts.
    ⚠Ensure flywheel is properly indexed to crankshaft. The bolt pattern is offset and will only fit correctly in one orientation.
12. 12

    Torque flywheel bolts
    Using the flywheel holding tool to prevent rotation, torque the flywheel bolts in a crisscross pattern to the specified torque value. Verify all bolts are properly torqued.
13. 13

    Install clutch disc and pressure plate
    Clean the flywheel friction surface with brake cleaner. Position the new clutch disc against the flywheel with the damper springs facing the transmission (the side marked 'transmission side' or 'flywheel side' accordingly). Insert the clutch alignment tool through the clutch disc and into the pilot bearing to center the disc. Position the new pressure plate over the clutch disc, aligning the dowel pins. Install new pressure plate bolts and tighten gradually in a crisscross pattern to the specified torque. Remove the alignment tool.
14. 14

    Reinstall transmission
    Apply a small amount of high-temperature grease to the input shaft splines. Position the transmission on the transmission jack and roll into position under the vehicle. Raise the transmission into alignment with the engine. Carefully slide the transmission forward, ensuring the input shaft enters the clutch disc splines and pilot bearing. The transmission should slide in smoothly without force. If resistance is met, recheck alignment and rotate the transmission output shaft slightly to align splines. Once fully seated, install all bellhousing-to-engine bolts and torque to specification.
    ⚠Do not force the transmission into position. If it does not slide in smoothly, the input shaft is likely not aligned with the clutch disc splines.
15. 15

    Reinstall crossmember and mount
    Raise the transmission slightly and position the crossmember into place. Install the crossmember-to-frame bolts and torque to specification. Install the transmission mount-to-crossmember bolts and torque to specification. Remove the transmission jack.
16. 16

    Reconnect components
    Reinstall the starter motor and connect the starter wiring. Torque starter bolts to specification. Reconnect the reverse light switch and vehicle speed sensor connectors. Reconnect the shift linkage to the transmission shift arms and secure with retaining clips. Install the hydraulic slave cylinder to the bellhousing and connect the hydraulic line at the quick-disconnect fitting.
17. 17

    Reinstall driveshaft
    Clean the transmission output shaft splines and apply a thin layer of high-temperature grease. Slide the driveshaft forward onto the transmission output shaft. Align the driveshaft to the differential flange using the alignment marks made during removal. Install the 4 driveshaft-to-differential bolts and torque to specification.
18. 18

    Reinstall exhaust and refill transmission
    Reinstall the exhaust system using new gaskets as needed. Torque all exhaust fasteners to specification. Refill the transmission with 4.2 quarts of OEM-specified manual transmission fluid (verify against 2008 Viper service manual) through the fill plug on the side of the transmission case. Fill until fluid begins to drip from the fill hole, then install the fill plug. Note: Refill the transmission with the OEM-specified quantity of the factory-specified manual transmission fluid (verify exact fluid type and capacity against the 2008 Viper service manual) through the fill plug on the side of the transmission case.

Reassembly

1. Remove engine support fixture.
2. Reconnect negative battery cable.
3. Lower vehicle from jack stands or lift.

Verification

• Start the engine and verify no abnormal noises from the clutch or flywheel area.
• With the engine running, depress the clutch pedal and verify smooth engagement and disengagement.
• Test drive the vehicle through all gears, verifying smooth shifting and no clutch slippage under load.
• Check for fluid leaks around the transmission and hydraulic clutch line.
• Listen for any rattling or abnormal vibration that could indicate improper flywheel installation or imbalance.
• Verify clutch pedal feel is normal with proper engagement point.

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