Pilot Bearing

This procedure covers removal and replacement of the pilot bearing in a 2007 Ram 3500 with 5.9L Cummins diesel, requiring transmission and clutch assembly removal.

Warnings

Tools required

Parts

• Pilot bearing × 1 — Use OEM or quality aftermarket bearing
• Clutch kit (if worn) × 1 — Inspect and replace if needed
• Transmission input shaft seal × 1 — Replace while transmission is removed
• Bellhousing to engine gasket or RTV sealant × 1 — Check for reusable gasket or use RTV
• Transmission mounting hardware × 1 — Inspect and replace if damaged

Fluids

• 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 both battery cables, negative first
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove skid plates and belly pans if equipped
5. Allow exhaust system to cool completely before beginning work
6. Place drain pans under transmission and transfer case drain plugs
7. Take photos of wiring harness routing and shifter linkage positions for reference

Procedure

1. 1

   Drain transmission and transfer case
   Remove drain plug from transmission and allow fluid to drain completely into pan. Remove transfer case drain plug and drain fluid. Remove fill plugs to ensure complete drainage and allow venting.
2. 2

   Remove transfer case
   Disconnect front and rear driveshafts at transfer case flanges after marking orientation. Disconnect shift linkage, speed sensors, and vent hoses. Support transfer case with jack and remove mounting bolts. Carefully lower and remove transfer case from vehicle.
3. 3

   Disconnect transmission components
   Disconnect clutch hydraulic line at slave cylinder. Disconnect reverse light switch, speed sensor, and any other electrical connectors. Remove shift tower or shifter linkage depending on transmission model. Support engine with jack or support bar across engine compartment.
4. 4

   Remove transmission crossmember
   Support transmission with transmission jack. Remove crossmember mounting bolts at frame rails. Carefully lower transmission slightly and remove crossmember from vehicle. Ensure transmission jack is positioned to support full weight.
5. 5

   Remove transmission to bellhousing bolts
   Remove all bellhousing to engine block bolts working from top and bottom. There are several bellhousing to engine block bolts of varying lengths (verify exact count and locations for your transmission during removal). Keep bolts organized by location. Inspect for any ground straps or wiring clips attached to bellhousing.
6. 6

   Remove transmission assembly
   With assistant or second jack supporting weight, carefully slide transmission rearward keeping input shaft aligned with clutch splines. Once input shaft clears clutch disc and pilot bearing, carefully lower transmission away from vehicle. Be prepared for significant weight - NV5600 transmission weighs approximately 250 lbs.
7. 7

   Access and remove clutch assembly
   Mark pressure plate position relative to flywheel for balanced reinstallation. Gradually loosen pressure plate bolts in criss-cross pattern, loosening each 2-3 turns at a time to prevent warping. Remove pressure plate and clutch disc. Inspect clutch components for wear, hot spots, or damage.
8. 8

   Remove pilot bearing
   Insert pilot bearing puller into bearing bore. The pilot bearing is pressed into the crankshaft center bore. Use slide hammer with internal puller attachment or thread-type puller to extract bearing. If bearing is seized, carefully apply penetrating oil and allow to soak. Avoid damaging crankshaft bore during removal.
9. 9

   Inspect and prepare crankshaft bore
   Clean crankshaft pilot bearing bore thoroughly with solvent and wire brush or scotch-brite pad. Remove any rust, debris, or old grease. Inspect bore for scoring or damage. Check flywheel mounting surface for cracks and measure runout if dial indicator available - should be less than 0.010 inch.
10. 10

    Install new pilot bearing
    Pack new pilot bearing with high temperature bearing grease - fill approximately 1/3 full, not completely packed. Install bearing with seal side facing outward (toward transmission). Use pilot bearing installation tool or appropriately sized socket that contacts outer race only. Drive bearing in squarely until seated flush with crankshaft bore face or to manufacturer specification depth.
11. 11

    Install clutch assembly
    Place clutch disc on flywheel with marked side facing pressure plate (or stamped 'flywheel side' toward flywheel). Insert clutch alignment tool through disc and into pilot bearing to center disc. Position pressure plate aligned with marks made during removal. Install pressure plate bolts hand tight, then tighten gradually in criss-cross pattern. Consult service manual for the proper torque specification for your specific clutch/pressure plate assembly and tighten to that value. Remove alignment tool after pressure plate is secured.
12. 12

    Prepare transmission for installation
    Inspect transmission input shaft for wear, burrs, or damage. Clean input shaft splines with solvent. Apply thin coat of high temperature grease to input shaft splines and release bearing contact points. Inspect transmission input shaft seal and replace if any leakage visible. Verify release bearing moves freely on input shaft bearing retainer.
13. 13

    Install transmission
    Apply thin bead of RTV sealant to bellhousing mating surface if no gasket used, or install new gasket. Position transmission on jack and align with engine. Carefully slide transmission forward, guiding input shaft through clutch disc splines and into pilot bearing. Clutch alignment tool must have been removed first. Do not force - input shaft must slide freely. If binding occurs, recheck clutch disc alignment. Install bellhousing bolts and tighten in criss-cross pattern.
14. 14

    Install crossmember and transfer case
    Raise transmission to correct height and install crossmember. Tighten crossmember bolts to specification. Reconnect all transmission electrical connectors, shift linkage, and hydraulic clutch line. Position transfer case on jack, align with transmission output shaft, and install. Torque transfer case mounting bolts. Reconnect driveshafts with alignment marks matched. Reconnect all transfer case wiring and linkage.
15. 15

    Refill fluids and final checks
    Install drain plugs in transmission and transfer case. Refill transmission with the manufacturer-specified manual transmission fluid (NV5600 uses synthetic MTF such as Mopar Manual Transmission Lubricant/Castrol Syntorq, approximately 4.4 quarts; verify exact fluid and capacity in the service manual for your specific transmission). Refill transfer case with ATF+4 to the correct level (approximately 2.0 quarts for NV271/NV273; verify capacity and fill to the bottom of the fill plug hole). Verify all electrical connections are secure. Check that all mounting bolts are tight. Bleed clutch hydraulic system if air entered system during disconnection.

Reassembly

1. Reinstall any skid plates or belly pans removed during disassembly
2. Reconnect battery cables, positive first, then negative
3. Double-check that all driveshaft bolts are properly torqued and aligned
4. Verify transmission and transfer case are filled to proper levels

Verification

• Start engine and verify no fluid leaks from transmission, transfer case, or clutch hydraulic system
• Depress clutch pedal and verify smooth engagement with normal pedal feel - bleed system if spongy
• With engine running and clutch depressed, shift through all gears to verify smooth engagement
• Test drive vehicle and verify clutch engages smoothly without slipping or chatter
• Check for any unusual noises from transmission or transfer case during operation
• Verify 4WD engagement operates properly if equipped
• Recheck fluid levels after test drive and top off if necessary

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