Transmission Rebuild - Automatic

Complete removal, disassembly, rebuild, and reinstallation of the A-518 (46RH) automatic transmission in a 1992 Dodge Viper, including torque converter replacement and valve body reconditioning.

Warnings

Tools required

Parts

• A-518 master rebuild kit with clutches and steels × 1 — Use OEM specification
• Torque converter (if damaged or worn) × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Transmission pan gasket or RTV sealant × 1 — Use OEM specification
• Rear main seal (inspect during removal) × 1 — Use OEM specification
• Transmission mount × 1 — Use OEM specification
• Driveshaft U-joint hardware × 1 — Use OEM specification
• Transmission fluid ATF+3 × 12 — Mopar ATF+3 or equivalent
• Thread locking compound (medium strength) × 1 — Loctite 242 or equivalent
• Assembly lube × 1 — Petroleum jelly or specific transmission assembly lube

Fluids

• ATF+3 automatic transmission fluid — 12 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery cable.
3. Raise vehicle on lift or support securely on jack stands at all four corners with sufficient clearance for transmission removal (minimum 36 inches).
4. Remove both side sill covers and lower underbody panels to access transmission from below.
5. Mark driveshaft-to-differential flange orientation with paint pen for proper reassembly alignment.
6. Prepare clean workspace for transmission disassembly with organized parts trays labeled by subassembly.
7. Review factory service manual internal clearance specifications for this A-518 transmission variant.

Procedure

1. 1

   Drain transmission fluid
   Place large drain pan under transmission. Remove transmission pan bolts in criss-cross pattern, loosening one corner last to allow controlled draining. Once fluid has drained, remove pan completely and set aside. Remove transmission filter by pulling straight down from valve body. Inspect pan for metal debris or clutch material that would indicate internal damage.
2. 2

   Disconnect electrical and mechanical connections
   Disconnect throttle valve cable from transmission lever by removing cable clip and sliding cable end out of lever slot. Disconnect transmission range sensor (neutral safety switch) electrical connector at transmission case. Disconnect vehicle speed sensor connector. Disconnect transmission cooler lines at transmission case using flare nut wrench; plug lines and transmission ports immediately to prevent contamination.
   ⚠Throttle valve cable adjustment is critical for proper shift quality. Mark cable position before removal or note adjustment for reinstallation.
3. 3

   Remove driveshaft
   Remove four driveshaft flange bolts connecting driveshaft to rear differential (previously marked for alignment). Support driveshaft center and slide rearward out of transmission output shaft. Install transmission output seal protector or wrap tape around output shaft splines to prevent damage to rear seal during removal.
   ⚠Do not allow driveshaft to drop or hang unsupported as this can damage U-joints.
4. 4

   Support engine and remove crossmember
   Position engine support bar across engine bay or attach chain hoist to engine lift points. Support engine weight. Remove four transmission crossmember mounting bolts and remove crossmember from vehicle. Remove transmission mount from transmission if mount is being replaced.
5. 5

   Remove torque converter access cover and converter bolts
   Remove transmission bellhousing inspection cover (typically four bolts). Rotate flexplate using breaker bar on crankshaft bolt to access all four torque converter-to-flexplate bolts through inspection opening. Remove all four bolts and push torque converter back into transmission bellhousing to disengage from flexplate. Mark converter orientation to flexplate if reusing converter.
   ⚠Torque converter must be pushed fully rearward into transmission pump before lowering transmission or it will fall out during removal.
6. 6

   Remove transmission-to-engine mounting bolts
   Support transmission securely on transmission jack with adapter or support fixture. Remove all transmission bellhousing-to-engine block bolts. On the A-518 behind the 8.0L V10, there are six bellhousing bolts in total. Ensure transmission is fully supported on jack before removing final bolts.
7. 7

   Remove transmission from vehicle
   With assistant steadying transmission, pull transmission straight back away from engine approximately 2 inches to disengage input shaft from pilot bearing. Verify torque converter remains fully seated in transmission pump (converter lugs should be approximately 1 inch recessed from bellhousing face). Lower transmission on jack and roll out from under vehicle. Secure torque converter to transmission with converter holding strap or wire to prevent it from sliding out.
   ⚠️Transmission weighs approximately 200 pounds. Do not attempt removal without proper transmission jack and assistant.
8. 8

   Mount transmission in rebuild stand and disassemble extension housing
   Mount transmission securely in transmission rebuild stand or on sturdy workbench. Remove speedometer gear and housing from extension housing. Remove extension housing bolts and carefully slide extension housing off output shaft. Remove output shaft seal from extension housing and set housing aside. Remove extension housing bushing if worn.
   ℹ️Keep all components organized in labeled containers by subassembly to ensure correct reassembly.
9. 9

   Remove valve body assembly
   Remove transmission oil pan mounting surface gasket material. Position transmission with pan side up. Remove valve body bolts (typically 14-16 bolts of varying lengths; note locations). Carefully lower valve body assembly, keeping manual valve engaged with detent lever until ready to separate. Disconnect park rod from valve body before full removal. Tag all valve body bolt locations for reassembly.
10. 10

    Disassemble front pump and measure endplay
    Remove front pump retaining bolts (typically six bolts). Before removing pump, install dial indicator on input shaft and measure input shaft endplay by moving input shaft in and out. Record reading (specification typically 0.022-0.091 inches). Pry pump assembly from case using case pry points; do not damage pump sealing surface. Remove pump seal and front clutch assembly from pump.
11. 11

    Remove clutch assemblies and planetary gearsets
    Remove front clutch assembly (direct clutch) from case. Remove rear clutch assembly (forward clutch). Remove front planetary gearset and thrust washers (note thrust washer positions and thickness). Remove rear planetary gearset. Remove low-reverse drum assembly. Keep all thrust washers organized and measure thickness for proper clearance verification during reassembly.
    ⚠Thrust washer location and thickness is critical for proper endplay. Document each washer location with photos or detailed notes.
12. 12

    Remove output shaft, governor, and parking pawl assembly
    Remove output shaft assembly from case. Remove governor assembly from output shaft; inspect governor weights and springs for wear. Remove snap ring retaining parking pawl shaft. Remove parking pawl, spring, and shaft. Inspect parking pawl for wear on engagement surface.
    ℹ️Governor weights control shift points. Ensure weights move freely and springs have proper tension.
13. 13

    Inspect and clean all components
    Thoroughly wash all hard parts in transmission solvent. Blow dry with compressed air (wear eye protection). Inspect all clutch drums for scoring, cracks, or heat damage. Inspect all planetary gear teeth for wear, chips, or damage. Check all bushings for excessive wear (should have minimal radial play). Inspect case for cracks, stripped threads, or worn servo bores. Replace any damaged hard parts.
    ⚠️Use only compressed air with proper eye protection. Debris in eyes can cause serious injury.
14. 14

    Disassemble and rebuild clutch packs
    For each clutch assembly (front and rear clutches, and low-reverse drum), remove large snap ring retaining pressure plate. Remove pressure plate, clutch plates, and steel separator plates in order (document plate count and order). Use clutch pack compressor to compress return springs and remove snap ring. Remove piston assembly using compressed air applied to clutch apply passage. Remove and discard all seals from pistons. Install new seals from rebuild kit using assembly lube. Install new springs if included in kit. Reassemble clutch pack with new friction plates and steels per rebuild kit specifications, soaking all friction plates in Mopar ATF+ (7176) for minimum 30 minutes before assembly.
    ⚠Apply compressed air gradually when removing pistons. Piston can eject forcefully causing injury.
    ⚠Ensure all friction plates are fully soaked in ATF before installation to prevent initial slip and burn-in damage.
15. 15

    Measure and verify clutch pack clearances
    After assembling each clutch pack with new components, measure clutch pack clearance using feeler gauge between pressure plate and snap ring. Front clutch clearance specification is typically 0.029-0.057 inches. Rear clutch clearance specification is typically 0.036-0.097 inches. Low-reverse clutch clearance specification is typically 0.020-0.040 inches. Adjust clearance if needed using selective snap rings or by adding/removing steel plates per service manual specifications.
16. 16

    Rebuild valve body assembly
    Disassemble valve body on clean workbench (work over large clean pan to catch springs and check balls). Remove all valve body bolts and separate sections. Remove all valves, springs, and check balls, organizing in sequence. Inspect all valves for scoring or wear. Clean all passages with solvent and blow dry. Install new separator plate gaskets. Install all valves, springs, and check balls per service manual diagrams and check ball chart. Reinstall valve body sections with new gaskets, torquing bolts to specification in sequence.
    ⚠Valve body contains numerous small springs and check balls that can easily be lost. Work in contained area and document locations carefully.
17. 17

    Reassemble transmission case with clutch assemblies and gearsets
    Lubricate all thrust washers with assembly lube and position in case per documentation from disassembly. Install output shaft assembly. Install parking pawl assembly with new spring if worn; secure with snap ring. Install low-reverse clutch drum. Install rear planetary gearset with correct thrust washers. Install rear clutch assembly. Install front planetary gearset with correct thrust washers. Install front clutch assembly, ensuring proper engagement with rear clutch and planetary components.
    ℹ️Rotate assemblies as installed to verify proper engagement and free rotation without binding.
18. 18

    Install front pump assembly
    Install new front pump bushing if worn. Install new front seal in pump housing using seal driver. Lubricate pump seal lips with assembly lube. Install new pump-to-case O-ring or gasket. Position pump assembly on case, ensuring input shaft engages with front clutch. Rotate input shaft while pushing pump into case to ensure proper engagement. Install pump bolts finger-tight, then torque in criss-cross pattern to specification (typically 17-20 lb-ft). Verify input shaft endplay is within specification measured earlier.
19. 19

    Install valve body and verify operation
    Position transmission with pan side up. Install governor assembly on output shaft; verify smooth operation. Connect park rod to valve body. Position valve body assembly on case, engaging manual valve with detent lever. Install all valve body bolts in correct locations per documentation. Torque valve body bolts to specification (typically 35-40 inch-pounds in criss-cross pattern). Verify manual valve moves smoothly through all gear positions.
20. 20

    Install extension housing and external components
    Install new extension housing bushing if worn. Install new output shaft seal in extension housing using seal driver. Lubricate seal lip with assembly lube. Install new extension housing gasket. Slide extension housing onto output shaft and case. Install extension housing bolts and torque to specification (typically 25 lb-ft). Install speedometer gear and housing with new O-ring. Install transmission range sensor and vehicle speed sensor if removed.
21. 21

    Install transmission filter and pan
    Install new transmission filter on valve body; press firmly into place to seat O-ring. Clean transmission pan thoroughly and inspect for damage. Install new pan gasket or apply RTV sealant per manufacturer specification (if using RTV, apply thin continuous bead and allow to set per product instructions). Position pan on case. Install pan bolts finger-tight, then torque in criss-cross pattern to specification.
    Torque spec

    Transmission Pan Bolts12 Nm (9 lb-ft)
22. 22

    Prepare torque converter for installation
    Inspect torque converter for cracks, damaged hub, or damaged pilot. If reusing converter, flush thoroughly with solvent to remove debris. Pour 1-2 quarts of Mopar ATF+ (7176) into converter. Rotate converter to distribute fluid. Position converter on front pump and rotate while pushing inward to engage pump drive. Verify converter is fully seated by measuring distance from bellhousing face to converter ear; should be approximately 1 inch recessed. Verify converter rotates freely.
    ⚠Converter must be fully engaged with pump or it will crack case during installation. Verify proper engagement depth before installation.
23. 23

    Install transmission in vehicle
    With transmission securely mounted on transmission jack and torque converter secured with holding strap, position transmission under vehicle. Raise transmission into position, aligning input shaft with engine crankshaft. Remove converter holding strap. Carefully slide transmission forward, ensuring input shaft engages pilot bearing and torque converter hub engages crankshaft. Do not force transmission forward; if resistance is felt, lower and realign. Once transmission is fully seated against engine block, install all bellhousing bolts and torque to specification.
    ⚠️Never draw transmission to engine using mounting bolts. Transmission must slide forward freely when properly aligned.
24. 24

    Install torque converter to flexplate
    Rotate flexplate to access all converter bolt holes through bellhousing inspection opening. Install four torque converter-to-flexplate bolts, aligning marks made during disassembly if reusing converter. Start all bolts finger-tight, then torque in star pattern to specification. Install bellhousing inspection cover and secure with bolts. Note: Torque converter-to-flexplate bolts are standard fasteners; inspect threads and replace if damaged. Verify torque spec with service manual.
    ℹ️Torque converter bolts may be TTY (torque-to-yield) and require replacement. Verify with service manual.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
25. 25

    Install crossmember and remove engine support
    Install transmission mount to transmission if removed. Position crossmember under transmission mount. Install crossmember mounting bolts and torque to specification. Remove engine support bar or hoist once crossmember is secured.
26. 26

    Install driveshaft and reconnect components
    Remove protective tape from output shaft. Align driveshaft with marks made during removal. Slide driveshaft into transmission output shaft, ensuring proper engagement. Install four driveshaft flange bolts and torque to specification (typically 60 lb-ft). Reconnect transmission cooler lines using new washers if applicable; torque fittings to specification. Reconnect all electrical connectors: transmission range sensor, vehicle speed sensor. Reconnect throttle valve cable to transmission lever and adjust per service manual procedure.
    ⚠Throttle valve cable must be properly adjusted or transmission will not shift correctly and may be damaged.
27. 27

    Fill transmission with fluid and perform initial checks
    Pour approximately 4 quarts of Mopar ATF+ (7176) into transmission through dipstick tube. Start engine and allow to idle. With parking brake engaged and foot on brake pedal, shift through all gear ranges, pausing 2-3 seconds in each position. Return to Park. Check fluid level on dipstick (should be in ADD range when cold). Add fluid to bring to ADD mark. Run engine until transmission reaches operating temperature (10-15 minutes of operation), then recheck fluid level with engine running in Park. Fluid should be in HOT range. Add fluid as needed to reach proper level.
    ⚠Do not overfill transmission. Overfilling can cause foaming, overheating, and seal leaks.
28. 28

    Perform road test and final adjustments
    Test drive vehicle to verify all shifts occur at proper points and without harshness. Verify kickdown functions properly under wide-open throttle. Check for fluid leaks at pan, cooler lines, and all seals. If shifts are delayed or harsh, verify throttle valve cable adjustment. Recheck fluid level after road test with transmission at operating temperature. Document baseline shift characteristics for future reference.
    ℹ️New clutch materials may cause slightly firmer shifts initially. Shift quality should normalize within 50-100 miles as clutches burnish.

Reassembly

1. Reverse removal procedure for all components not specifically addressed in rebuild steps
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Verify all fluid connections are secure and leak-free before final testing
4. Double-check throttle valve cable adjustment before road test
5. Install any underbody panels or protective covers removed during access

Verification

• Verify transmission engages all gear ranges (P, R, N, D, 2, 1) without delay or harsh engagement
• Verify upshifts and downshifts occur at appropriate speeds under normal throttle
• Verify kickdown (passing gear) engages under wide-open throttle
• Verify no fluid leaks at pan, pump seal, rear seal, cooler lines, or sensor locations after test drive
• Verify proper fluid level at operating temperature (HOT range on dipstick with engine running in Park)
• Verify no abnormal noises from transmission during operation in any gear
• Verify parking pawl holds vehicle securely on incline when in Park

Related trouble codes on this vehicle

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