Transmission R&R - Automatic

Complete removal and reinstallation of the automatic transmission on a 1992 Dodge Viper, including driveshaft, torque converter, crossmember, and all electrical connections.

Warnings

Tools required

Parts

• Transmission drain plug washer × 1 — Use OEM specification
• Torque converter bolts (if reusing is not recommended) × 4 — Use OEM specification
• Transmission pan gasket (if pan removal required) × 1 — Use OEM specification
• Driveshaft U-joint straps or bolts × 1 — Inspect and replace if worn
• Transmission mount (inspect for wear) × 1 — Use OEM specification

Fluids

• ATF+3 automatic transmission fluid — 10 qt

Preparation

1. Verify vehicle is equipped with automatic transmission (A-518/46RH). Some 1992 Vipers may have manual transmission.
2. Park vehicle on level surface and engage parking brake firmly.
3. Disconnect negative battery cable to prevent electrical shorts.
4. Raise vehicle using floor jack and support securely on jack stands rated for vehicle weight, positioned on frame rails.
5. Place wheel chocks behind rear wheels for additional safety.
6. Remove rear wheels to improve access to rear suspension and exhaust components.
7. Allow transmission and exhaust system to cool completely if vehicle was recently operated.
8. Place drain pan under transmission to catch fluid during drain and disconnection procedures.

Procedure

1. 1

   Drain transmission fluid
   Locate transmission drain plug on bottom of transmission pan. Position drain pan beneath drain plug. Remove drain plug using appropriate socket and allow fluid to drain completely (approximately 4-6 quarts will drain from pan; remainder stays in torque converter and cooler lines). Inspect drain plug and washer for damage. Set aside drain plug and discard old washer.
   Torque spec

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

   Remove exhaust components
   Disconnect exhaust system at the connection point behind the transmission. On the 1992 Viper, this typically requires removing the exhaust flange bolts where the front and rear exhaust sections meet. Support the rear exhaust section and remove the flange fasteners. Lower the rear exhaust section out of the way and support with wire or rope to prevent strain on hangers. You may need to remove exhaust hangers for additional clearance.
3. 3

   Remove driveshaft
   Mark the driveshaft-to-differential flange relationship with paint or scribe marks for proper reinstallation alignment. Remove the 4 driveshaft flange bolts at the rear differential. Support the driveshaft and carefully slide it rearward to separate from the transmission output shaft. Use caution not to let the driveshaft drop and damage the universal joints. Cap the transmission extension housing with a plug or plastic bag secured with tape to prevent fluid leakage and contamination entry.
   ⚠Driveshaft weighs approximately 25-30 lbs. Support properly during removal to prevent universal joint damage.
4. 4

   Disconnect transmission cooler lines
   Locate the two transmission cooler lines connected to the right side of the transmission case. Place drain pan beneath connections as residual fluid will drain. Using a flare nut wrench to prevent rounding, loosen and disconnect both cooler lines from the transmission fittings. Cap or plug both the transmission ports and the cooler line ends immediately to prevent fluid loss and contamination. Secure lines out of the way.
5. 5

   Disconnect electrical connections and shift linkage
   Disconnect the transmission wiring harness connectors. This vehicle is not equipped with an automatic transmission; disregard automatic-specific electrical connections. If servicing the T-56 manual, disconnect the reverse lockout solenoid, backup light switch, and any applicable sensor connectors. Label each connector for reinstallation reference. Disconnect the throttle valve (TV) cable from the transmission lever by releasing the locking tab and unhooking the cable end. Disconnect the shift linkage by removing the retaining clip at the transmission shift lever and sliding the linkage rod off the ball stud. Secure linkage away from work area. Note: This vehicle uses a manual transmission with no throttle valve (TV) cable. Disregard TV cable procedures.
   ⚠The throttle valve (TV) cable adjustment is critical for proper transmission operation. Mark the cable position before removal.
6. 6

   Disconnect speedometer cable or vehicle speed sensor
   Locate the vehicle speed sensor (VSS) or mechanical speedometer cable connection at the transmission extension housing on the driver side. If electronic VSS, disconnect the electrical connector and remove the sensor retaining bolt, then carefully extract the sensor. If mechanical cable, unscrew the cable retaining nut from the transmission housing and carefully pull the cable out. Cap or cover the transmission opening.
7. 7

   Remove torque converter access cover and mark converter
   Locate the torque converter dust cover/inspection plate on the bottom of the bellhousing between the engine and transmission. Remove the cover fasteners and remove the cover plate. Rotate the engine crankshaft using a breaker bar on the crankshaft bolt to bring each torque converter-to-flexplate bolt into view through the access opening. Mark the torque converter-to-flexplate relationship with paint for proper reinstallation alignment.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
8. 8

   Remove torque converter-to-flexplate bolts
   With the torque converter visible through the access opening, remove the 4 bolts securing the torque converter to the flexplate. Rotate the crankshaft as needed to access each bolt. Use an impact wrench or breaker bar as these bolts are typically tight. Once all bolts are removed, push the torque converter back toward the transmission slightly to ensure it is free from the flexplate. The converter should move 1/4 to 1/2 inch rearward.
   ⚠Torque converter must be pushed back into transmission and secured before removing transmission to prevent it from falling out during removal.
9. 9

   Support engine and transmission
   Position a transmission jack under the transmission pan, centering the jack saddle for proper balance. Secure transmission to jack using safety chains or straps. The transmission weighs approximately 200 lbs and must be properly supported. Optionally, support the rear of the engine using an engine support fixture from above, or place a floor jack with wood block under the oil pan (be careful not to damage the pan). The engine will need support once the transmission crossmember is removed.
10. 10

    Remove transmission crossmember
    Locate the transmission crossmember that supports the rear of the transmission. Remove the two bolts securing the transmission mount to the crossmember. Then remove the crossmember-to-frame fasteners on both sides (typically 2-4 bolts per side depending on design). With all fasteners removed, lower the crossmember away from the vehicle. Carefully lower the transmission jack slightly to provide working clearance for bellhousing bolt access.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Remove transmission-to-engine bellhousing bolts
    Locate all transmission-to-engine bellhousing bolts around the perimeter of the bellhousing. On the A-518 transmission behind the 8.0L V10, there are typically 6-8 bolts of varying lengths securing the transmission to the engine block. Note the location and length of each bolt as they must be reinstalled in the correct positions. Remove all bellhousing bolts using appropriate extensions and universal joints as needed for access.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Separate and remove transmission
    With all bolts removed and transmission supported on jack, carefully pull the transmission straight back away from the engine. The transmission must move rearward approximately 2-3 inches to fully disengage the torque converter hub from the engine crankshaft. Use caution to keep the transmission level and prevent binding. As the transmission separates, verify the torque converter remains fully seated in the transmission pump (should be recessed approximately 1/2 to 3/4 inch from bellhousing face). Use a C-clamp or torque converter holding tool to secure the converter to the bellhousing to prevent it from sliding out. Once fully separated from engine, carefully lower the transmission on the jack and roll it out from under the vehicle. Keep transmission level during removal to prevent torque converter from falling out.
    ⚠️Transmission weighs approximately 200 lbs. Maintain positive control on transmission jack at all times. Ensure torque converter is secured before lowering.
    ⚠Do not allow transmission input shaft or torque converter hub to hang on engine components during removal. This can damage the transmission pump seal or bushing.

Reassembly

1. Before installation, verify torque converter is fully seated in transmission pump by measuring the distance from bellhousing mounting face to front of converter hub. It should be recessed at least 1/2 inch. Rotate converter while pushing to ensure full engagement with pump drive.
2. Inspect flexplate for cracks or damage. Replace if any damage is found. Clean flexplate and torque converter mounting surfaces.
3. Apply a small amount of high-temperature grease to torque converter pilot hub.
4. With transmission on jack, carefully raise and align transmission with engine block. Ensure torque converter hub aligns with crankshaft center. Slide transmission forward slowly, rotating torque converter as needed to engage splines. Transmission should slide fully forward until bellhousing seats against engine block with minimal force. Do not force - if binding occurs, check alignment.
5. Install all bellhousing bolts in their original locations and torque to specification. Tighten in a crisscross pattern to ensure even seating.
6. Remove torque converter holding tool. Rotate crankshaft to align torque converter bolt holes with flexplate access holes. Install torque converter-to-flexplate bolts and torque to specification in a star pattern.
7. Reinstall transmission crossmember and mount. Torque all fasteners to specification. Remove transmission jack only after crossmember is fully secured.
8. Reinstall torque converter dust cover.
9. Reconnect speedometer cable or vehicle speed sensor with new O-ring if equipped.
10. Reconnect shift linkage to transmission shift lever and secure with retaining clip. Verify smooth movement through all gear positions.
11. Reconnect throttle valve (TV) cable to transmission lever and adjust per factory specification. Proper TV cable adjustment is critical for transmission operation and shift quality.
12. Reconnect all electrical connectors (neutral safety switch, backup lights, solenoid pack) ensuring they click firmly into place.
13. Remove caps from transmission cooler line ports and cooler lines. Install cooler lines to transmission using new O-rings if equipped. Torque fittings to specification using flare nut wrench to prevent damage.
14. Align driveshaft marks made during removal and install driveshaft to differential flange. Install and torque flange bolts to specification.
15. Reinstall exhaust system components and secure all hangers. Torque exhaust flange bolts to specification.
16. Install new drain plug washer and reinstall transmission drain plug. Torque to specification.
17. Reinstall rear wheels if removed and torque lug nuts to specification.
18. Lower vehicle from jack stands.
19. Reconnect negative battery cable.
20. Fill transmission with ATF+3 fluid through dipstick tube. Initial fill capacity is approximately 4-5 quarts to bring fluid to ADD mark on dipstick. Total system capacity is approximately 10 quarts but much remains in torque converter during drain.
21. Adjust shift linkage: With transmission in Park and ignition in Lock position, verify park pawl engages. Adjust linkage rod length if needed so all gear positions align properly with shifter detents.
22. Verify throttle valve (TV) cable adjustment: With throttle fully closed, cable should have minimal slack. At wide-open throttle, cable should pull transmission lever to full travel position without binding throttle linkage.

Verification

• Start engine and verify transmission engages in all gear positions (P, R, N, D, 3, 2, 1) smoothly without unusual noise.
• With engine at operating temperature and idling in Park, check transmission fluid level on dipstick. Add fluid as needed to bring level to HOT mark. Do not overfill.
• Check for fluid leaks at drain plug, cooler line connections, speedometer sensor, and pan gasket. Repair any leaks immediately.
• Perform test drive to verify proper transmission operation: smooth shifts in all gears, proper shift points, no slipping, and no unusual noises.
• Verify backup lights illuminate in Reverse and vehicle will only start in Park or Neutral (neutral safety switch function).
• Recheck fluid level after test drive with engine idling in Park on level surface. Adjust as needed.
• Inspect under vehicle for any fluid leaks or loose components after test drive.
• Verify exhaust system has proper clearance and does not contact driveshaft or transmission at any point of suspension travel.

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