Pressure Plate

This procedure covers removal and replacement of the pressure plate on a 2007 Ram 3500 with 5.9L Cummins diesel and manual transmission, requiring transmission removal.

Warnings

Tools required

Parts

• Pressure plate assembly × 1 — Use OEM or performance clutch kit specification
• Clutch disc × 1 — Included in clutch kit
• Pilot bearing × 1 — Use OEM specification
• Throwout bearing (release bearing) × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Transmission to transfer case gasket × 1 — Use OEM specification
• Transfer case output seal (if applicable) × 1 — Use OEM specification

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. Place wheel chocks behind rear wheels.
2. Disconnect both battery cables, negative first, then positive.
3. Raise vehicle and support securely on jack stands at frame rails. Ensure adequate working clearance underneath.
4. Remove skid plates and belly pans if equipped.
5. Drain transmission fluid into appropriate container by removing fill and drain plugs.
6. Drain transfer case fluid into appropriate container.
7. Mark front and rear driveshaft positions relative to their flanges with paint or punch marks.
8. Allow exhaust system to cool completely if vehicle was recently driven.

Procedure

1. 1

   Remove driveshafts
   Remove the rear driveshaft by unbolting the flange bolts at the differential and transfer case. Remove front driveshaft by unbolting at front differential and transfer case. Support driveshafts and lower carefully to avoid damaging the U-joints. Cap transfer case outputs to prevent contamination.
2. 2

   Disconnect shift linkage and wiring
   Disconnect the shift tower linkage at the transmission. On G56 transmissions, remove the reverse light switch connector and any speed sensor connectors. Disconnect the clutch hydraulic line at the slave cylinder (may be internal on some models). For external slave cylinders, unbolt and secure out of the way.
3. 3

   Remove crossmember and support transmission
   Position transmission jack under transmission pan with wood block to distribute load. Raise jack slightly to take weight off crossmember. Remove crossmember mounting bolts and lower crossmember away. Support transfer case with additional jack or stand.
4. 4

   Separate transfer case from transmission
   Remove the transfer case to transmission mounting bolts (typically 6-8 bolts). Carefully slide transfer case rearward off transmission output shaft while supporting weight with jack. Lower transfer case and set aside. Inspect and replace output seal if showing any leakage.
5. 5

   Remove transmission mounting bolts
   Remove all transmission to bellhousing bolts. On the G56, there are typically 8-10 bolts of varying lengths around the perimeter. Note bolt locations and lengths for reassembly. Check for any ground straps or brackets that must be removed.
6. 6

   Remove transmission
   Carefully slide transmission rearward on jack, ensuring input shaft clears clutch disc and pilot bearing. The transmission is heavy and requires controlled movement. Once input shaft is clear, lower transmission and remove from under vehicle. Keep transmission level to avoid damaging input shaft or internal components.
7. 7

   Inspect clutch and flywheel
   Inspect the clutch disc for wear, oil contamination, or glazing. Check flywheel surface for heat checking, cracks, or excessive wear. Measure flywheel runout if tooling available (should be under 0.010 inches). Check pilot bearing for roughness by spinning with finger. Inspect throwout bearing for wear or noise.
8. 8

   Remove pressure plate
   Mark pressure plate position relative to flywheel for balance if reusing. Gradually loosen pressure plate bolts in a crisscross pattern, turning each bolt 1-2 turns at a time to prevent warping. Once all tension is released, remove bolts completely and carefully remove pressure plate and clutch disc. Note which direction clutch disc faces.
9. 9

   Replace pilot bearing
   Remove old pilot bearing from crankshaft using appropriate puller tool or slide hammer. Clean pilot bearing bore in crankshaft thoroughly. Install new pilot bearing squarely into crankshaft bore, driving in evenly until fully seated. Lubricate bearing lightly with high-temperature grease.
10. 10

    Install new clutch disc and pressure plate
    Clean flywheel surface with brake cleaner. Position new clutch disc against flywheel with correct orientation (damper springs typically face transmission, 'flywheel side' marking should face flywheel). Insert clutch alignment tool through disc and into pilot bearing. Position new pressure plate over dowel pins, aligning marks if reusing original. Install pressure plate bolts hand-tight.
11. 11

    Torque pressure plate bolts
    Tighten pressure plate bolts gradually in a crisscross star pattern. Make multiple passes, tightening each bolt incrementally to avoid warping. Final torque specification is approximately 40-45 ft-lbs for the G56/Cummins pressure plate (verify exact value against OEM spec and clutch kit instructions). Ensure clutch alignment tool remains centered throughout process. Remove alignment tool only after all bolts are fully torqued.
12. 12

    Install throwout bearing and prepare for transmission
    Install new throwout bearing onto transmission input shaft bearing retainer or clutch fork (depending on design). Lubricate input shaft splines lightly with high-temperature grease. Inspect the front bearing retainer and its seal; replace if leaking or worn (G56-specific part). Verify throwout bearing moves freely and is properly secured.
13. 13

    Reinstall transmission
    Raise transmission into position with transmission jack, keeping it level. Carefully align input shaft with clutch disc splines and pilot bearing. Slide transmission forward, rotating output shaft slightly if needed to align splines. Once input shaft is fully engaged and transmission is flush against bellhousing, install all mounting bolts in their correct locations. Tighten bolts evenly in a star pattern to specification (typically 40-50 ft-lbs for bellhousing bolts).
14. 14

    Reinstall transfer case and complete assembly
    Install new gasket or sealant on transmission to transfer case mating surface. Align transfer case with transmission output shaft and slide forward onto transmission. Install and tighten all transfer case mounting bolts. Reinstall crossmember and torque mounting bolts. Reconnect shift linkage, hydraulic clutch line, and all electrical connectors. Install front and rear driveshafts, aligning marks made during disassembly and torquing flange bolts.
15. 15

    Refill fluids and final checks
    Refill transfer case with ATF+4, filling until fluid reaches the bottom of the fill plug hole (approximately 2 quarts). Refill transmission through fill plug with the specified G56 manual transmission fluid (per Chrysler spec, SAE 5W-40 CJ-4 synthetic engine oil, approximately 6.5 quarts) until fluid reaches bottom of fill hole. Reinstall all skid plates and belly pans. Lower vehicle and reconnect battery cables (positive first, then negative). Verify all connections are secure and no tools remain in engine bay or under vehicle.

Reassembly

1. Double-check all driveshaft flange bolts are torqued properly to prevent vibration or separation
2. Ensure clutch hydraulic system is properly bled if line was disconnected (pump clutch pedal and check for firm feel)
3. Verify shift linkage is properly adjusted and all gears engage smoothly before test driving
4. Check for any fluid leaks from transmission, transfer case, or driveshaft seals after refilling

Verification

• Start engine and verify no unusual noises from bellhousing area
• With engine running, depress clutch pedal and verify smooth, quiet operation without binding or chattering
• Shift through all gears with engine off and clutch depressed to verify proper clutch release
• Test drive vehicle and verify smooth clutch engagement without slipping, chattering, or grabbing
• Check clutch pedal feel for proper height and engagement point (typically 2-3 inches from floor)
• Recheck transmission and transfer case fluid levels after test drive
• Inspect for any fluid leaks around transmission, transfer case, and driveshaft connections
• Verify no driveline vibrations are present at various speeds

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