60K Service

Complete 60,000-mile scheduled maintenance service including fluid changes, filter replacements, spark plugs, and comprehensive inspection of all major systems on the 1992 Dodge Viper 8.0L V10.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Use OEM specification
• Air filter element × 1 — Use OEM specification
• Spark plugs × 10 — Champion RC12LYC or equivalent
• Fuel filter × 1 — Use OEM specification
• Drain plug washer (differential) × 1 — Use OEM specification
• Drain plug washer (transmission) × 1 — Use OEM specification

Fluids

• 10W-30 conventional engine oil — 11 qt
• Mopar MS-9224 or 75W-90 GL-4 manual transmission fluid — 4.2 qt
• 75W-90 GL-5 with limited-slip additive rear differential fluid — 3.5 qt
• Ethylene glycol 50/50 coolant — 1 qt
• DOT 3 brake fluid — 0.5 qt
• Mopar power steering fluid or ATF+3 — 0.25 qt

Preparation

1. Park vehicle on level surface and allow engine, transmission, and differential to cool to ambient temperature (minimum 2 hours after operation).
2. Engage parking brake and place wheel chocks behind rear wheels.
3. Gather all fluids, filters, and parts. Verify spark plug gap specification (0.035 inch for Champion RC12LYC).
4. Raise vehicle using floor jack at designated lift points and support securely on jack stands at all four corners.
5. Remove all four wheels and set aside for tire inspection and rotation.

Procedure

1. 1

   Drain engine oil and replace filter
   Locate oil drain plug on passenger side of oil pan. Place drain pan beneath plug and remove drain plug using appropriate socket. Allow oil to drain completely (approximately 10-15 minutes). While draining, remove oil filter located on driver side of engine block using oil filter wrench. Clean filter mounting surface and apply thin film of fresh oil to new filter gasket. Install new filter hand-tight plus 3/4 turn. Reinstall drain plug once oil has fully drained.
2. 2

   Drain and refill manual transmission
   Locate transmission fill plug on passenger side of transmission case (upper position) and drain plug on bottom of case. Remove fill plug first to verify it is not seized. Place drain pan beneath transmission and remove drain plug. Allow fluid to drain completely. Install new drain plug washer and reinstall drain plug. Using fluid transfer pump, refill transmission through fill hole with the factory-specified fluid and capacity (verify exact fluid type and quantity in FSM for the Borg-Warner T-56) until fluid begins to seep from fill hole. Reinstall fill plug.
3. 3

   Drain and refill rear differential
   Locate differential cover drain plug at bottom of differential housing. Remove fill plug on driver side of differential first to verify accessibility. Place drain pan beneath differential and remove drain plug. Allow fluid to drain completely. Install new drain plug washer and reinstall drain plug. Using fluid transfer pump, add the factory-specified quantity of 75W-90 GL-5 gear oil (verify exact capacity in FSM) along with appropriate amount of limited-slip additive (typically 4 oz, verify on additive bottle) through fill hole until fluid reaches bottom of fill hole threads. Reinstall fill plug.
4. 4

   Replace fuel filter
   Locate fuel filter mounted on driver side frame rail near fuel tank. Relieve fuel system pressure by removing fuel pump relay (located in power distribution center) and running engine until it stalls. Place shop towels around filter to catch residual fuel. Note direction of flow arrow on filter body. Using appropriate wrenches, disconnect fuel lines from both ends of filter. Remove filter from mounting bracket. Install new filter in correct flow direction and reconnect fuel lines. Reinstall fuel pump relay.
5. 5

   Replace air filter element
   Open hood and locate air filter housing on driver side of engine compartment. Release housing clips and separate upper housing from lower section. Remove old air filter element and inspect housing for debris or moisture. Clean housing interior if necessary. Install new air filter element ensuring proper seating. Reassemble housing and secure all clips.
6. 6

   Replace spark plugs (Bank 1 - driver side)
   Disconnect spark plug wire boots from plugs on driver side cylinders (5 cylinders). Mark or tag wires if necessary to ensure correct reinstallation order. Using spark plug socket and extension, remove all 5 spark plugs from driver side bank. Inspect plug condition and electrode wear. Gap new spark plugs to the factory specification (verify exact gap in FSM before installation). Apply anti-seize compound sparingly to plug threads (avoid getting compound on electrodes). Install new plugs hand-tight, then torque to specification. Reconnect spark plug wires ensuring proper seating of boots.
7. 7

   Replace spark plugs (Bank 2 - passenger side)
   Disconnect spark plug wire boots from plugs on passenger side cylinders (5 cylinders). Mark or tag wires if necessary. Using spark plug socket and extension, remove all 5 spark plugs from passenger side bank. Inspect plug condition. Gap new spark plugs to 0.035 inch. Apply anti-seize compound sparingly to plug threads. Install new plugs hand-tight, then torque to specification. Reconnect spark plug wires ensuring proper seating.
8. 8

   Refill engine oil
   Lower vehicle partially to access oil filler cap on passenger side valve cover. Using funnel, add the factory-specified quantity of synthetic oil (verify viscosity — original spec was Mobil 1 15W-50) per the owner's manual. Start engine and allow to run for 30 seconds, then shut off. Wait 2 minutes for oil to drain back to pan. Check oil level on dipstick and add remaining oil in 0.5 quart increments until level reaches full mark. Verify total capacity in the FSM before filling (commonly around 8 quarts with filter).
9. 9

   Inspect and top off coolant system
   With engine cool, locate coolant recovery tank on driver side of engine bay. Check coolant level against cold full mark on tank. If low, add 50/50 ethylene glycol coolant mixture to bring to proper level. Inspect radiator hoses, heater hoses, and clamps for deterioration, cracks, or leaks. Check coolant condition for contamination or discoloration. Note any concerns for future service.
10. 10

    Inspect and top off brake fluid
    Locate brake fluid reservoir on master cylinder (driver side firewall). Check fluid level against maximum mark. If low, add DOT 3 brake fluid to bring to proper level. Inspect fluid color (should be clear to light amber). Dark or contaminated fluid indicates need for complete flush. Inspect brake lines and hoses visible from underneath for damage, corrosion, or leaks.
11. 11

    Inspect and top off power steering fluid
    Locate power steering reservoir on passenger side of engine bay. With engine cold, check fluid level against cold mark on dipstick or reservoir. Add Mopar power steering fluid or ATF+3 if needed. Inspect power steering hoses and lines for leaks, cracks, or damage. Check steering rack boots for tears or leaks.
12. 12

    Inspect belts, hoses, and drive system
    Inspect serpentine belt for cracks, glazing, fraying, or abnormal wear. Check belt tension (should have approximately 1/2 inch deflection with moderate thumb pressure at longest span). Inspect all visible coolant hoses for cracks, soft spots, or bulging. Check all visible vacuum lines for deterioration. Inspect CV boots on halfshafts for tears or grease leakage. Note any items requiring future replacement.
13. 13

    Rotate and inspect tires
    With wheels already removed, inspect tire tread depth (minimum 4/32 inch), abnormal wear patterns indicating alignment issues, and sidewall condition. Check for embedded objects or damage. Do NOT rotate tires — the Viper uses staggered, directional tires with different front and rear sizes that cannot be rotated. Inspect tires in place and reinstall on original corners. Reinstall wheels and torque lug nuts to specification in star pattern. Lower vehicle completely and perform final torque check on all lug nuts with wheels on ground.
14. 14

    Set tire pressures and perform final inspection
    Adjust all tire pressures to specification listed on driver door jamb placard. Perform walk-around inspection checking for fluid leaks underneath vehicle. Start engine and verify no warning lights remain illuminated. Check for smooth idle and proper oil pressure reading. Allow engine to reach operating temperature and verify cooling fan operation. Recheck all fluid levels with engine at operating temperature. Test drive vehicle to verify proper operation of all systems.

Reassembly

1. Dispose of used oil, transmission fluid, differential fluid, and old filters at appropriate recycling facility.
2. Reset maintenance reminder if equipped.
3. Record service date, mileage, and all work performed in vehicle maintenance log.

Verification

• Verify no fluid leaks present under vehicle after test drive and overnight parking.
• Confirm oil level is at full mark on dipstick with engine at operating temperature.
• Verify all warning lights extinguish after engine start.
• Confirm smooth engine operation with no misfires or rough idle.
• Verify proper tire pressure in all four tires.
• Check that all drain plugs and fill plugs are secure with no seepage.

More procedures for this vehicle