Flywheel

This procedure covers removal and replacement of the flywheel or flexplate on a 2007 Ram 3500 with the 5.9L Cummins diesel engine, requiring transmission removal to access the component.

Warnings

Tools required

Parts

• Flywheel (manual) or Flexplate (automatic) × 1 — Use OEM specification
• Flywheel bolts or flexplate bolts × 1 — Check if TTY bolts requiring replacement
• Rear main seal × 1 — Recommended replacement during this procedure
• Transmission to engine gasket or RTV sealant × 1 — Use OEM specification
• Pilot bearing (manual transmission only) × 1 — Use OEM specification

Fluids

• ATF+4 (automatic transmission) — 20 qt
• ATF+4 (manual transmission) — 8 qt
• ATF+4 (transfer case) — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable, then positive battery cable
3. Raise vehicle and support securely on jack stands positioned on frame rails
4. Remove skid plates and belly pans if equipped
5. Allow transmission fluid and transfer case fluid to drain if replacing seals or performing service
6. Mark driveshaft positions relative to yokes with paint pen for reinstallation alignment
7. Take photos of electrical connections and linkages for reference during reassembly

Procedure

1. 1

   Remove driveshafts
   Remove the rear driveshaft by removing the four bolts at the differential yoke and the four bolts at the transfer case yoke. Remove the front driveshaft by removing bolts at the front differential and transfer case. Support driveshafts and carefully remove from vehicle. Cap transfer case outputs to prevent fluid loss.
2. 2

   Disconnect transmission linkages and wiring
   Disconnect the shift linkage from the transmission (for automatic, disconnect shift cable; for manual, remove shifter assembly or disconnect linkage). Disconnect all electrical connectors from the transmission including speed sensors, solenoid pack connector (automatic), reverse light switch (manual), and any other sensors. Label connections for reassembly.
3. 3

   Remove transmission cooler lines and exhaust components
   For automatic transmissions, disconnect transmission cooler lines at the transmission using line wrenches to prevent damage. Cap lines and transmission ports immediately. Remove any exhaust components that interfere with transmission removal, typically requiring removal of exhaust from the turbo back to past the transmission crossmember.
4. 4

   Support and remove transfer case
   Position a transmission jack or support stand under the transfer case. Remove the transfer case to transmission mounting bolts (typically 6 bolts). Mark the position of the transfer case relative to the transmission for proper indexing during reinstallation. Carefully slide the transfer case rearward off the transmission output shaft and lower from vehicle. Be prepared for residual ATF+4 to drain.
5. 5

   Remove transmission crossmember and support transmission
   Position a transmission jack under the transmission, centering it on the transmission pan. Remove the transmission mount to crossmember bolts. Remove the crossmember to frame bolts and remove the crossmember from the vehicle. Ensure the transmission jack is securely supporting the full weight of the transmission before proceeding. Refill transmission with the correct fluid and quantity (48RE automatic: approximately 17-18 quarts ATF+4 dry-fill, verify; G56 manual: approximately 4.75 quarts of Mopar manual transmission fluid MS-9224 / 75W-85 GL-4, NOT ATF+4)
6. 6

   Disconnect starter and inspection cover
   Remove the starter motor by disconnecting the positive battery cable connection and solenoid wire, then removing the mounting bolts. Remove the starter from the bellhousing. Remove the inspection/dust cover from the bottom of the bellhousing to access the flywheel/flexplate bolts.
7. 7

   Remove transmission to engine bolts
   Remove all bellhousing to engine block bolts. On the 5.9L Cummins, these are typically located around the perimeter of the bellhousing. There are usually 6-8 bolts of varying lengths. Note the location and length of each bolt for proper reinstallation. Ensure the transmission jack is positioned properly before removing the final bolts.
8. 8

   Separate transmission from engine
   With an assistant or using the transmission jack carefully, slide the transmission straight back away from the engine. The input shaft must clear the pilot bearing (manual) or torque converter must remain with the transmission (automatic). Move slowly and ensure nothing is binding. Lower the transmission and remove from under the vehicle. For automatic transmissions, secure the torque converter to prevent it from falling out.
9. 9

   Lock flywheel and remove flywheel bolts
   Install a flywheel holding tool to lock the flywheel/flexplate in place, or use a starter ring gear lock. Mark the position of the flywheel/flexplate relative to the crankshaft with a paint pen for proper balance during reinstallation. Remove all flywheel or flexplate bolts in a crisscross pattern. Keep bolts organized and inspect for stretching if reusing (check TTY specification).
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Flexplate Bolts85 Nm (63 lb-ft)
10. 10

    Remove and inspect flywheel
    Carefully remove the flywheel or flexplate from the crankshaft. Inspect the flywheel friction surface for hot spots, cracks, scoring, or glazing. Check for loose ring gear. Inspect flexplate for cracks, especially around bolt holes and in the center section. If reusing the flywheel, measure runout with a dial indicator mounted to the engine block (maximum 0.010 inch runout allowed). Inspect the pilot bearing (manual transmission) for wear or roughness and replace if necessary.
11. 11

    Inspect and replace rear main seal
    With the flywheel removed, carefully inspect the rear main seal for leaks. This is an ideal time to replace the rear main seal as access is already achieved. Remove the old seal using a seal puller or carefully with a screwdriver, taking care not to damage the crankshaft or seal bore. Clean the seal bore thoroughly. Install the new seal using a seal driver or large socket, ensuring it seats evenly and squarely. Lubricate the seal lip with clean engine oil before installation.
12. 12

    Clean and prepare mounting surfaces
    Thoroughly clean the crankshaft flange and flywheel/flexplate mounting surfaces using brake cleaner and a clean rag. Remove any oil, dirt, or debris. Inspect crankshaft bolt threads and clean with a thread chaser if necessary. Ensure all surfaces are completely dry before installation. For manual transmissions, install a new pilot bearing in the crankshaft using a pilot bearing installation tool, ensuring it is fully seated.
13. 13

    Install flywheel to crankshaft
    Align the new or resurfaced flywheel/flexplate to the crankshaft using the alignment marks made during removal. Install new flywheel or flexplate bolts if they are TTY type. Hand-thread all bolts to prevent cross-threading. Using the flywheel holding tool to prevent rotation, tighten the bolts in a star pattern to the specified torque. For flywheel (manual), torque to the Cummins factory specification (approximately 137 Nm / 101 lb-ft — verify against FSM as multi-stage torque may apply). For flexplate (automatic), torque to the Cummins factory specification (approximately 137 Nm / 101 lb-ft — verify exact multi-stage spec against FSM). Perform final tightening in multiple passes (50%, 75%, then 100% torque).
    ⚠Use a star/crisscross tightening pattern to ensure even clamping force and prevent flywheel warping.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
14. 14

    Prepare transmission for installation
    For automatic transmissions, verify the torque converter is fully seated in the transmission (should click into place three times as it engages the pump). Measure the distance from the bellhousing face to the torque converter mounting lugs to confirm proper seating. For manual transmissions, inspect the clutch disc, pressure plate, and release bearing for wear and replace as necessary while access is available. Apply a thin coat of high-temperature grease to the input shaft splines.
15. 15

    Reinstall transmission to engine
    With assistance or using the transmission jack, carefully align the transmission to the engine. For manual transmissions, align the input shaft with the pilot bearing and clutch disc splines. For automatic transmissions, ensure the torque converter remains fully seated and aligns with the flexplate. Slide the transmission forward, ensuring proper alignment. Do not force; if resistance is met, recheck alignment. Install and hand-tighten all bellhousing to engine bolts, then torque in a star pattern per manufacturer specification.
16. 16

    Install flexplate to torque converter bolts
    For automatic transmissions only: Rotate the crankshaft using a socket on the crankshaft bolt to access each torque converter to flexplate bolt hole through the inspection cover opening. Install all torque converter bolts and tighten to the 48RE factory specification (approximately 23 lb-ft / 31 Nm — verify exact spec against FSM). Use thread locker if specified. Ensure all bolts are properly seated before final tightening.
17. 17

    Complete transmission installation
    Install the transmission crossmember and torque mounting bolts to specification. Install transmission mount bolts and torque to specification. Remove the transmission jack. Reinstall the starter motor and torque mounting bolts to specification. Reconnect starter wiring. Install the inspection cover. Reconnect all transmission electrical connectors, shift linkage, and cooler lines (for automatic). Install the transfer case in the indexed position and torque mounting bolts to specification.

Reassembly

1. Reinstall front and rear driveshafts, aligning marks made during disassembly and torquing yoke bolts to specification
2. Reinstall any exhaust components that were removed
3. Refill transfer case with 2.5 quarts of ATF+4
4. Refill transmission with appropriate amount of ATF+4 (20 quarts for automatic, 8 quarts for manual)
5. Reinstall skid plates and belly pans if equipped
6. Reconnect battery cables (positive first, then negative)
7. For automatic transmissions, check transmission fluid level with engine running in Park after reaching operating temperature

Verification

• Start the engine and listen for any unusual noises from the flywheel or transmission area
• Check for fluid leaks around the rear main seal, transmission bellhousing, and transfer case
• For manual transmissions, verify smooth clutch engagement and release without chattering or slipping
• For automatic transmissions, verify smooth shifting through all gears and proper torque converter lockup
• Test drive the vehicle and verify normal operation under various load conditions
• Recheck all fluid levels after test drive and top off as necessary
• Inspect underneath the vehicle after test drive for any fluid leaks
• Verify no vibration occurs during acceleration which could indicate flywheel imbalance

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