Transmission Output Shaft Bearing

This procedure covers removal and replacement of the transmission output shaft bearing on the 1992 Dodge Viper with 6-speed manual transmission, requiring transmission removal and partial disassembly.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification
• Transmission rear seal × 1 — Use OEM specification
• Rear cover gasket × 1 — Use OEM specification or RTV sealant
• Transmission fluid drain plug washer × 1 — Use OEM specification
• Clutch alignment tool for Viper × 1 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery cable.
3. Raise vehicle on lift to comfortable working height and ensure secure support.
4. Remove both rear wheels if additional access is required for exhaust work.
5. Place drain pan under transmission and allow adequate cool-down time if vehicle was recently operated.

Procedure

1. 1

   Drain transmission fluid
   Locate transmission drain plug on bottom of transmission case. Remove drain plug and allow fluid to drain completely into drain pan. Inspect drained fluid for metal particles or debris indicating additional internal damage. Reinstall drain plug with new washer.
   Torque spec

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

   Remove driveshaft
   Mark alignment between driveshaft flange and rear differential flange using paint pen or scribe. Remove the bolts securing driveshaft to differential flange (verify exact count against factory service manual). Support driveshaft and slide rearward to disengage from transmission output shaft. Do not allow universal joints to bind at extreme angles. Remove driveshaft from vehicle and cap transmission output housing to prevent fluid leakage.
3. 3

   Disconnect shift linkage and electrical connections
   Disconnect shift rod at transmission shift lever by removing retaining clips. Disconnect reverse light switch electrical connector on driver side of transmission. Disconnect vehicle speed sensor connector if equipped. Label all connections for proper reassembly.
4. 4

   Remove exhaust components
   Remove exhaust hangers supporting intermediate exhaust pipes in transmission tunnel area. Lower or remove exhaust sections as needed to provide clearance for transmission removal. On 1992 Viper, the side-exit exhaust routing typically requires disconnecting at collector flanges and removing heat shields around transmission.
5. 5

   Support engine and remove transmission crossmember
   Install engine support fixture across engine bay or attach lifting chain to engine lift points. Raise support fixture to take weight off transmission mounts. Place transmission jack under transmission and secure with safety chain. Remove the bolts securing transmission crossmember to frame rails (verify exact count against factory service manual). Remove crossmember from vehicle.
6. 6

   Remove bellhousing to engine bolts
   Working from underneath and through top access, remove all bellhousing bolts securing transmission to engine block. On the Viper V10, remove all bellhousing bolts of varying lengths (verify exact count and length locations against factory service manual). Note location of each bolt for proper reinstallation. Ensure starter motor has been removed or repositioned if blocking access to lower bellhousing bolts.
7. 7

   Remove transmission from vehicle
   Verify all electrical connections, linkage, and mounting bolts are disconnected. Carefully slide transmission rearward on transmission jack, ensuring input shaft clears clutch splines without binding. Tilt transmission slightly nose-up as needed during removal to clear chassis components. Once input shaft is clear of bellhousing, lower transmission on jack and remove from under vehicle. Place transmission on sturdy workbench.
8. 8

   Remove transmission rear housing
   With transmission on bench, remove the bolts securing rear extension housing to transmission case. On the Borg-Warner T56 transmission used in the 1992 Viper, remove the bolts around perimeter of rear housing (verify exact count against factory service manual). Tap housing gently with deadblow hammer if stuck. Slide rear housing off output shaft, taking care not to damage rear seal.
9. 9

   Remove output shaft rear snap ring and speedometer gear
   Using internal snap ring pliers, remove snap ring securing speedometer drive gear on output shaft. Slide speedometer gear off shaft. Remove any additional snap rings or retainers securing output shaft bearing in position. Note exact position and orientation of all snap rings for proper reassembly.
10. 10

    Extract output shaft bearing
    Using appropriate bearing puller, carefully extract output shaft bearing from rear of output shaft. Position puller jaws behind bearing inner race only, not on outer race or roller elements. Apply steady pressure to avoid damaging output shaft. If bearing is severely damaged and inner race separates, use internal bearing puller to remove remaining race from shaft. Inspect output shaft bearing surface for scoring, wear, or damage requiring shaft replacement.
11. 11

    Inspect and measure components
    Using micrometer, measure output shaft diameter at bearing contact area. Compare to service specifications to verify shaft is not worn undersize. Inspect bearing bore in rear housing for scoring or damage. Measure bearing bore diameter if wear is suspected. Inspect all snap ring grooves for deformation. Check output shaft end play specification using dial indicator if internal transmission work is being performed.
12. 12

    Install new output shaft bearing
    Clean output shaft bearing surface thoroughly. Place new bearing on output shaft with manufacturer markings facing outward (rearward). Using bearing installation driver matching bearing inner race diameter, drive bearing onto shaft until fully seated against shoulder. Ensure bearing is square to shaft during installation to prevent cocking. Verify bearing rotates smoothly without binding after installation.
13. 13

    Reinstall snap rings and speedometer gear
    Install snap rings securing output shaft bearing in exact original positions. Ensure snap rings are fully seated in grooves with no gaps. Slide speedometer drive gear onto output shaft and secure with snap ring. Verify all components are secure and output shaft rotates freely.
14. 14

    Install rear housing with new seal
    Install new rear seal in rear extension housing using seal driver, with seal lip facing forward into transmission. Apply thin coat of transmission fluid to seal lip. Apply thin bead of RTV sealant to rear housing mating surface if gasket is not used, or install new gasket. Carefully slide rear housing over output shaft, ensuring seal is not damaged. Install and torque all rear housing bolts in criss-cross pattern.
15. 15

    Reinstall transmission in vehicle
    Apply light coat of high-temperature grease to input shaft splines. Verify clutch disc is properly aligned using clutch alignment tool. Raise transmission on transmission jack and carefully guide input shaft through bellhousing opening. Align input shaft splines with clutch disc splines and slide transmission forward until bellhousing mates flush with engine block. Install all bellhousing bolts and torque to specification in star pattern.
16. 16

    Install crossmember and remove engine support
    Position transmission crossmember and install mounting bolts. Torque crossmember bolts to specification. Carefully lower transmission jack and remove engine support fixture. Verify transmission is properly supported before removing jack.
17. 17

    Reconnect all components
    Reconnect shift linkage to transmission shift lever and install retaining clips. Reconnect reverse light switch and vehicle speed sensor electrical connectors. Reinstall exhaust components and secure all hangers. Align driveshaft marks and install driveshaft to differential flange, torquing bolts to specification. Install rear wheels if removed.
18. 18

    Fill transmission with fluid
    Remove transmission fill plug. Using fluid pump, fill transmission with 4.2 quarts of Mopar MS-9224 or 75W-90 GL-4 transmission fluid through fill hole. Fluid level is correct when fluid begins to seep from fill hole with vehicle level. Install fill plug and torque to specification.
    Torque spec

    Fill Plug34 Nm (25 lb-ft)

Reassembly

1. Installation is reverse of removal with the following notes:
2. Always use new transmission drain plug washer and rear seal.
3. Apply thread sealant to drain and fill plugs before installation.
4. Verify clutch disc is properly centered with alignment tool before installing transmission.
5. Torque all fasteners to specification in proper sequence.
6. Check transmission fluid level after test drive and top off as needed.

Verification

• Reconnect battery and start engine. Verify no fluid leaks from drain plug, fill plug, rear seal, or rear housing gasket.
• With engine running and clutch pedal depressed, shift through all gears to verify proper engagement.
• Test drive vehicle and verify smooth shifting in all gears with no grinding or binding.
• Check for unusual noise from transmission output shaft area, particularly in higher gears under load.
• After test drive, recheck transmission fluid level and inspect for any new leaks.
• Verify speedometer operation if vehicle is equipped with cable-driven speedometer.

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