Transmission R&R - Manual

Complete removal and installation procedure for the Borg-Warner T56 6-speed manual transmission in the 1992 Dodge Viper RT/10, including driveline disconnection, bellhousing separation, and transmission mounting.

Warnings

Tools required

Parts

• Transmission drain plug crush washer × 1 — Use OEM specification
• Clutch alignment tool (10-spline, 1.125-inch diameter) × 1 — Use OEM specification or universal equivalent
• Bellhousing gasket (if damaged) × 1 — Use OEM specification
• Rear transmission mount rubber isolator (inspect) × 1 — Use OEM specification

Fluids

• Mopar MS-9224 or 75W-90 GL-4 manual transmission fluid — 4.2 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery cable to prevent accidental starter engagement.
3. Raise vehicle and support securely on four jack stands positioned at manufacturer-recommended lift points.
4. Remove rear wheels if additional working clearance is needed for exhaust or driveshaft access.
5. Allow exhaust system to cool completely before beginning work (minimum 1 hour after engine operation).
6. Place drain pan under transmission drain plug location.

Procedure

1. 1

   Drain transmission fluid
   Locate the transmission drain plug on the bottom of the transmission case (verify presence for this T56 variant; some units require fluid extraction via the fill plug). Using the appropriate socket, remove the drain plug and allow fluid to drain completely into the drain pan. Inspect the condition of the crush washer on the drain plug and replace if damaged or compressed. Once drained, reinstall the drain plug with a new crush washer hand-tight; it will be torqued after transmission reinstallation.
   Torque spec

   Drain Plug34 Nm (25 lb-ft)
2. 2

   Remove shift knob and shifter boot assembly
   From inside the cabin, unscrew the shift knob counterclockwise to remove it from the shift lever. Pull the shifter boot upward to expose the shifter base mounting. The boot is retained by a trim ring that presses into the transmission tunnel opening; gently pry this upward to release it and expose the shift lever mechanism below.
3. 3

   Disconnect shift lever assembly
   The T56 transmission uses an internal shift tower that is accessed through the transmission tunnel. Locate the 4 bolts securing the shift tower to the top of the transmission case. Remove these bolts and lift the shift lever assembly straight up and out of the transmission. The shift lever pulls free from the shift rails inside the transmission; some resistance is normal. Cover the opening with a shop towel to prevent debris entry.
4. 4

   Mark and remove driveshaft
   Using a paint marker or scribe, mark the orientation of the rear driveshaft flange to the differential companion flange to maintain driveline balance. Remove the 4 bolts securing the rear U-joint straps to the differential flange. Pull the driveshaft rearward to disengage the slip yoke from the transmission output shaft. Support the driveshaft and remove it from under the vehicle. Inspect the slip yoke seal surface for damage.
5. 5

   Disconnect hydraulic clutch line
   Locate the hydraulic clutch line connection at the bellhousing where the slave cylinder mounts externally or internally depending on specific T56 variant. Verify the clutch actuation type for this vehicle: the 1992 Viper T56 may use an internal concentric slave cylinder (CSC) integrated with the release bearing rather than an external slave cylinder. Confirm configuration before proceeding. Remove the 2 bolts securing the slave cylinder to the bellhousing and carefully pull the cylinder away from the input shaft. Do not allow the cylinder to hang by the hydraulic line; secure it with wire to the chassis. Cap or plug the hydraulic line if fluid leakage occurs.
6. 6

   Disconnect electrical connectors
   Disconnect the reverse light switch connector located on the driver's side of the transmission case. The connector has a locking tab that must be depressed before pulling the connector free. Disconnect the speedometer drive at the tailhousing — verify whether this vehicle uses a mechanical speedometer cable (unscrew the cable retaining nut) or an electronic vehicle speed sensor (VSS) connector before proceeding. Press the retaining clip and pull the connector straight off the sensor body.
7. 7

   Remove exhaust system support and crossover
   The side-exit exhaust system on the 1992 Viper routes close to the transmission. Remove the exhaust hanger mounting bolts where the system is supported near the transmission crossmember. Depending on clearance, it may be necessary to loosen or remove the exhaust crossover pipe connection behind the transmission to allow sufficient downward clearance for transmission removal. Support the exhaust with wire or a jack to prevent damage to hangars.
8. 8

   Support transmission with transmission jack
   Position the transmission jack under the transmission pan area. Use a transmission adapter plate or secure wood block to distribute load and prevent pan damage. Raise the jack until it just contacts the transmission and takes slight preload, but do not lift the transmission at this point. Ensure the jack is centered under the transmission for balanced support during removal.
9. 9

   Remove transmission crossmember
   Locate the transmission crossmember that spans the frame rails and supports the rear of the transmission. Remove the 2 bolts securing the transmission mount to the crossmember. Then remove the 4 bolts securing the crossmember to the frame rails (2 per side). Lower the crossmember away from the vehicle. Inspect the transmission mount rubber isolator for cracking or deterioration and replace if necessary.
10. 10

    Remove bellhousing-to-engine bolts
    The T56 bellhousing is secured to the engine block with 6 bolts arranged around the perimeter of the bellhousing. Locate and remove all 6 bolts using appropriate socket and extension combinations. The upper bolts may require access from above through the engine bay. Some bolts may be difficult to access due to starter location and engine accessories; use universal joint adapters as needed. Keep bolts organized by location for reinstallation.
11. 11

    Separate transmission from engine and remove
    With all bolts removed and the transmission supported on the jack, carefully pull the transmission straight back away from the engine block. The transmission input shaft must slide out of the clutch disc and pilot bearing without binding. Move slowly and ensure the transmission remains level to avoid hanging the input shaft on the clutch. Once the input shaft clears the bellhousing opening (approximately 6 inches of rearward travel), tilt the front of the transmission slightly downward and continue pulling rearward. Lower the transmission jack and roll the assembly out from under the vehicle. The transmission weighs approximately 125 pounds; use care during handling.
12. 12

    Inspect clutch assembly and flywheel
    With the transmission removed, inspect the clutch disc for wear, oil contamination, and remaining friction material thickness. Check the pressure plate for signs of overheating (discoloration or cracking). Inspect the flywheel surface for hot spots, scoring, or excessive wear. Check the pilot bearing in the crankshaft for roughness by spinning it with a finger. If the clutch disc is worn below 0.030 inches of remaining friction material or shows oil contamination, replacement of the clutch assembly is recommended. Verify flywheel runout does not exceed 0.010 inches if resurfacing or replacement is being considered.
13. 13

    Prepare transmission for installation
    Clean the transmission input shaft splines with a wire brush and apply a thin coat of high-temperature grease to the splines. Do not over-grease, as excess can contaminate the clutch disc. Inspect the bellhousing mounting surface and transmission case mating surface for debris or damage. Install a new bellhousing gasket if the original is damaged or missing. Verify the clutch release bearing is properly seated on the input shaft bearing retainer and moves freely.
14. 14

    Align clutch disc using alignment tool
    Insert the clutch alignment tool (10-spline, 1.125-inch diameter) through the clutch disc and into the pilot bearing to ensure the disc is centered on the flywheel. The tool should slide through the disc splines and seat fully in the pilot bearing without resistance. This step is critical to allow the transmission input shaft to pass through the clutch disc during installation. Leave the alignment tool in place until the transmission is partially installed.
15. 15

    Install transmission onto engine
    Position the transmission on the transmission jack and roll it into position under the vehicle. Raise the transmission until it is roughly aligned with the engine block. Carefully guide the input shaft into the bellhousing opening, aligning it with the clutch alignment tool. Push the transmission forward slowly, allowing the input shaft to engage the clutch disc splines. If resistance is encountered, do not force it; rotate the output shaft slightly by hand to help align the splines. Once the input shaft is fully engaged, push the transmission forward until the bellhousing contacts the engine block. Remove the clutch alignment tool from the front of the engine. Ensure the bellhousing seats fully against the engine block before installing bolts.
16. 16

    Install bellhousing-to-engine bolts
    Install all 6 bellhousing-to-engine bolts and tighten them by hand initially. Once all bolts are started, torque them in a star pattern to ensure even seating of the bellhousing against the engine block. Use the specified torque value for mounting bolts. Verify the bellhousing is fully seated with no gaps between mating surfaces.
17. 17

    Install transmission crossmember and mount
    Raise the transmission slightly with the transmission jack to align the rear mount with the crossmember mounting location. Position the crossmember between the frame rails and install the 4 frame mounting bolts (2 per side). Hand-tighten these bolts first. Then install the 2 bolts securing the transmission mount to the crossmember and torque them to specification. Finally, torque the 4 crossmember-to-frame bolts to specification. Remove the transmission jack once the crossmember is fully secured.
18. 18

    Reconnect hydraulic clutch slave cylinder
    Position the hydraulic slave cylinder onto the bellhousing, aligning the pushrod with the clutch release bearing or fork mechanism. Install the 2 slave cylinder mounting bolts and torque them to specification. Ensure the hydraulic line is not kinked or strained. After installation, the clutch hydraulic system may require bleeding if the line was opened or if air entered the system during removal.
19. 19

    Install driveshaft
    Slide the driveshaft slip yoke into the transmission output shaft, ensuring it fully engages the output shaft splines. Align the rear U-joint flange with the differential companion flange using the alignment marks made during removal. Install the 4 U-joint strap bolts and torque them to specification. Verify the driveshaft rotates freely by hand and does not bind at any point in its rotation.
20. 20

    Reconnect electrical connectors
    Reconnect the vehicle speed sensor (VSS) connector at the tailhousing until the retaining clip clicks into place. Reconnect the reverse light switch connector on the driver's side of the transmission case, ensuring the locking tab fully engages. Gently pull on each connector to verify secure connection.
21. 21

    Reinstall exhaust system supports
    Raise the exhaust system back into position and secure any hangers or mounting brackets that were loosened or removed. If the exhaust crossover was disconnected, reconnect it and torque the connection bolts to specification. Ensure the exhaust system has adequate clearance from the transmission and driveshaft and does not contact any chassis or driveline components.
22. 22

    Install shift lever assembly
    Insert the shift lever assembly into the transmission shift tower opening from inside the cabin. Align the shift lever mechanism with the shift rails inside the transmission and press downward firmly until the tower seats against the transmission case. Install the 4 shift tower mounting bolts and torque them to specification. Verify the shift lever moves freely through all gear positions before proceeding.
23. 23

    Install shifter boot and shift knob
    Press the shifter boot trim ring into the transmission tunnel opening, ensuring it seats fully around the perimeter. Pull the boot material down over the trim ring to create a clean appearance. Thread the shift knob onto the shift lever clockwise and tighten firmly by hand. Some shift knobs have a set screw that must be tightened to prevent loosening during operation.
24. 24

    Refill transmission with fluid
    Locate the transmission fill plug on the side of the transmission case. Remove the fill plug using the appropriate socket. Using a fluid pump or funnel with extension hose, add the OEM-specified manual transmission fluid (verify type and capacity against factory service documentation for the 1992 Viper T56) through the fill hole. Fill until fluid begins to drip from the fill hole, indicating proper level. Reinstall the fill plug with a new crush washer if equipped and torque to specification. Torque the drain plug installed in Step 1 to specification at this time.
    Torque spec

    Fill Plug34 Nm (25 lb-ft)

    Drain Plug34 Nm (25 lb-ft)
25. 25

    Reconnect battery and perform final checks
    Reconnect the negative battery cable to the battery terminal. From inside the vehicle, with the engine off, depress the clutch pedal and shift through all gears to verify proper operation and engagement. Start the engine with the clutch depressed and the transmission in neutral. Listen for abnormal noises from the transmission or clutch area. Check for fluid leaks around the drain plug, fill plug, and all external seals. Lower the vehicle from jack stands and perform a short test drive to verify proper transmission operation under load.

Reassembly

1. Installation is the reverse of removal with the following critical notes: always use a clutch alignment tool to center the clutch disc before installing the transmission; torque all fasteners to specification in the order listed; ensure the driveshaft is installed in the original orientation per alignment marks; refill the transmission with the correct fluid type and quantity; bleed the hydraulic clutch system if any hydraulic connections were opened.

Verification

• Start the engine with the clutch pedal depressed and transmission in neutral. Listen for abnormal bearing noise or rattling from the transmission or clutch area.
• With the engine running, shift through all six forward gears and reverse while stationary (clutch depressed) to verify smooth gear engagement without grinding.
• Perform a test drive and verify smooth shifting under light and moderate throttle in all gears. Check for clutch slippage during acceleration in higher gears.
• Inspect under the vehicle for fluid leaks at the transmission drain plug, fill plug, bellhousing seal area, and slave cylinder hydraulic connection.
• Verify the reverse lights function when reverse gear is selected.
• Check that the shifter boot and trim are properly seated with no gaps or rattling.
• After the first 50-100 miles of operation, recheck the transmission fluid level and inspect for leaks as the system may settle.

Related trouble codes on this vehicle

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