Transmission Rebuild - Automatic

Complete removal, disassembly, rebuild, and reinstallation of the automatic transmission for the 2005 Dodge Viper with 8.3L V10 engine, including torque converter and valve body service.

Warnings

Tools required

Parts

• Automatic transmission master rebuild kit × 1 — Use OEM specification for Mercedes NAG1 W5A580
• Torque converter (if replacement needed) × 1 — Use OEM specification
• Transmission filter kit × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Front pump seal × 1 — Use OEM specification
• Output shaft seal × 1 — Use OEM specification
• Speed sensor O-rings × 2 — Use OEM specification
• Transmission cooler line O-rings × 4 — Use OEM specification
• Flexplate to torque converter bolts × 4 — Use OEM specification
• Transmission mounting bolts × 6 — Use OEM specification
• Assembly lubricant (transmission assembly lube) × 1 — Use petroleum jelly or ATF+4 compatible lube

Fluids

• ATF+4 automatic transmission fluid — 12 qt

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Disconnect negative battery cable and isolate from battery terminal.
3. Raise vehicle on lift to working height and ensure it is securely supported.
4. Remove engine cover and battery tray to access engine support fixture mounting points.
5. Install engine support fixture across inner fender wells to support engine weight during transmission removal.
6. Place drain pan under transmission and remove drain plug to drain transmission fluid.
7. Allow vehicle to cool completely if recently driven. Transmission fluid operating temperature exceeds 200°F.
8. Mark driveshaft and differential flange orientation for proper reinstallation alignment.

Procedure

1. 1

   Remove exhaust system components
   Unbolt exhaust system from manifold flanges. Support exhaust with stands and remove catalytic converter to transmission crossmember mounting hangers. Lower exhaust system enough to provide clearance for transmission removal. The side-exit exhaust on Viper requires complete removal of intermediate pipes from catalytic converters rearward.
2. 2

   Disconnect driveshaft
   Remove the 4 bolts securing rear driveshaft universal joint to differential flange. Push driveshaft forward and slide yoke out of transmission output shaft. Cap transmission output housing opening with a clean plastic bag to prevent fluid loss and contamination.
3. 3

   Disconnect transmission electrical connectors and cooler lines
   Disconnect transmission range sensor connector, input speed sensor, output speed sensor, and solenoid pack main connector from transmission case. Using line wrenches, carefully loosen and disconnect both transmission cooler lines at the transmission case fittings. Have drain pan positioned to catch residual fluid. Cap open lines and transmission ports to prevent contamination.
4. 4

   Remove shifter cable and support bracket
   Disconnect shifter cable from transmission range sensor lever by removing retaining clip and sliding cable end off ball stud. Unbolt shifter cable bracket from transmission case. Position cable out of work area without bending excessively.
5. 5

   Support transmission and remove crossmember
   Position transmission jack under transmission pan and secure transmission to jack with safety chain or adapter. Raise jack slightly to take weight off crossmember. Remove the 4 bolts securing transmission mount to crossmember, then remove the 2 bolts on each side securing crossmember to frame rails. Lower crossmember and remove from vehicle.
6. 6

   Remove torque converter dust cover and access bolts
   Remove bellhousing dust cover plate from bottom of bellhousing to expose flexplate and torque converter bolts. Rotate crankshaft using breaker bar on front crank bolt to access each of the 4 torque converter to flexplate bolts through access opening. Remove all 4 bolts and discard (these are torque-to-yield and must not be reused).
7. 7

   Remove transmission bellhousing bolts
   Remove all 6 transmission to engine block mounting bolts. Note the location of any ground straps or wiring harness brackets attached to these bolts for proper reinstallation. Upper bolts may require universal joint socket or extensions for access around frame rails and steering components.
8. 8

   Separate transmission from engine
   With transmission jack supporting full weight, carefully pull transmission straight back away from engine. Ensure torque converter remains fully seated in transmission front pump during removal. Once input shaft clears bellhousing, tilt transmission slightly nose-down and lower away from vehicle. Immediately secure torque converter to transmission housing with a strap or retaining tool to prevent it from sliding out and spilling fluid.
9. 9

   Mount transmission on rebuild stand and drain
   Remove torque converter from transmission and drain remaining fluid into pan. Mount transmission on rebuild stand in horizontal position with pan facing up. Remove all external sensors, solenoid connector, and wiring from case. Remove transmission pan bolts in criss-cross pattern, break pan seal carefully, and remove pan. Remove filter and valve body cover.
10. 10

    Remove valve body assembly
    Carefully note routing of all valve body wiring and pressure test ports. Disconnect internal mode switch connector and solenoid connectors at valve body. Remove the valve body mounting bolts (note different lengths and locations). Carefully lower valve body assembly away from case, keeping it level to prevent check balls from falling out. Place valve body on clean workbench and cover with clean shop towels. Count and document location of all check balls, springs, and components as valve body is disassembled.
11. 11

    Disassemble transmission case and clutch packs
    Remove front pump mounting bolts and extract front pump assembly using slide hammer or appropriate puller. Remove thrust washers and note orientation. Remove snap rings securing clutch pack assemblies. Using clutch pack spring compressor, compress clutch pack return springs and remove retaining snap rings. Extract clutch packs, documenting order and orientation of steel plates, friction discs, and pressure plates. Measure clutch pack clearances with feeler gauges and record measurements. Remove planetary gear sets, sun gear assemblies, and output shaft. Tag all components for reassembly position.
12. 12

    Inspect and measure all components
    Thoroughly clean all hard parts with solvent and dry with compressed air. Inspect all gear teeth for wear, pitting, or damage. Measure all thrust washer thicknesses with micrometer. Inspect all bushings for wear or scoring. Measure clutch plate thickness and check for glazing, burning, or warping. Inspect bands for lining wear or cracking. Check all snap ring grooves for damage. Inspect case for cracks, porosity, or stripped threads. Measure all shaft end play and clearances with dial indicator. Compare all measurements to manufacturer specifications and determine which components require replacement.
13. 13

    Replace seals, gaskets, and wear components
    Install all new seals from rebuild kit including front pump seal, output shaft seal, all O-rings, and case seals. Replace all friction clutch plates and steel plates as set (never mix old and new). Install new bands if equipped. Replace any bushings that show wear beyond specification. Install new thrust washers if measurements were out of specification. Replace all snap rings with new components from kit. Clean and inspect all solenoids; replace solenoid pack if any solenoids show wear or electrical faults.
14. 14

    Reassemble transmission internal components
    Lubricate all internal components with ATF+4 or approved assembly lubricant. Install output shaft and planetary gear assemblies in reverse order of removal, ensuring all thrust washers and bearings are properly positioned with correct end play. Install clutch pack assemblies with new friction plates and steels, alternating as per service manual. Use clutch spring compressor to install return springs and secure with new snap rings. Verify each clutch pack clearance with feeler gauge matches the manufacturer-specified value for that pack, selecting shims as required. Apply assembly lubricant to all seal rings and O-rings during installation.
15. 15

    Install front pump assembly
    Install new front pump seal and O-ring. Lubricate front pump bushing and seal lip with ATF+4. Carefully align front pump with case and input shaft splines. Install front pump evenly using new bolts or studs, tightening in criss-cross pattern to specified torque. Verify input shaft rotates freely and has correct end play per specification.
16. 16

    Reassemble and install valve body
    Reassemble valve body with all new seals, gaskets, and check balls from rebuild kit. Install check balls in exact locations as documented during disassembly. Install all springs and valve components in correct orientation. Install valve body separator plate with new gasket. Position valve body assembly into case, ensuring all manual valve linkages and solenoid connectors align properly. Install valve body bolts to specification, following tightening sequence from center outward. Install new filter and valve body cover with new gasket.
17. 17

    Install transmission pan and external components
    Clean transmission pan thoroughly and install with new gasket. Install pan bolts and tighten in criss-cross pattern to specification. Install all external sensors with new O-rings lubricated with ATF+4. Connect all electrical connectors. Install drain plug with new seal or O-ring.
18. 18

    Inspect and install torque converter
    Inspect torque converter for damage, leaks, or contamination. If clutch material was damaged during disassembly, torque converter must be replaced to prevent re-contamination. Measure torque converter hub for wear. Install new torque converter or cleaned/flushed original. Lubricate converter hub seal surface and pump bushing with ATF+4. Install torque converter into transmission, rotating while pushing until it fully engages pump drive (you should feel the converter step inward through each internal spline engagement as it fully seats). Measure and verify converter depth from bellhousing mounting surface; converter hub should be recessed approximately 0.5-1.0 inch from mounting surface to ensure proper engagement.
19. 19

    Install transmission to engine
    Apply small amount of high-temp grease to torque converter hub and input shaft splines. Verify torque converter is fully seated in pump. Raise transmission into position using transmission jack, carefully aligning input shaft with crankshaft pilot and torque converter with flexplate. Slide transmission forward, rotating slightly if needed to engage splines. Do not use mounting bolts to draw transmission to engine. Install all 6 transmission to engine mounting bolts with any ground straps or brackets in original positions.
20. 20

    Install torque converter to flexplate bolts
    Rotate crankshaft to align first torque converter bolt hole with flexplate. Install new torque converter to flexplate bolt through access opening and hand tighten. Rotate crankshaft to access remaining holes and install remaining 3 new bolts. Using flywheel holding tool to prevent rotation, torque all 4 bolts to specification in star pattern.
21. 21

    Reinstall crossmember and transmission mount
    Raise transmission slightly with jack. Position crossmember into frame rail mounts and install bolts hand tight. Install transmission mount to crossmember bolts. With all crossmember and mount bolts started, align and torque frame rail bolts first, then transmission mount bolts to specification. Remove transmission jack.
22. 22

    Reconnect all external components
    Install bellhousing dust cover. Connect shifter cable to transmission range sensor lever and install cable bracket to case. Connect all electrical connectors to transmission (range sensor, input speed sensor, output speed sensor, solenoid pack). Install transmission cooler lines with new O-rings, torquing fittings to specification using line wrenches. Install driveshaft, aligning marks made during removal, and torque U-joint bolts.
23. 23

    Reinstall exhaust system
    Raise exhaust system into position and connect to catalytic converter flanges and transmission crossmember hangers. Install all exhaust mounting hardware and torque to specification. Ensure adequate clearance exists between exhaust and driveshaft throughout full suspension travel.
24. 24

    Fill transmission and perform initial checks
    Remove engine support fixture. Lower vehicle. Add approximately 5 quarts of ATF+4 through dipstick tube. Reconnect battery negative cable. Start engine and allow to idle. Check under vehicle for any fluid leaks at pan, cooler lines, or case seals. With engine at idle and parking brake engaged, shift through all gear ranges, pausing 3 seconds in each position. Return to Park. Check fluid level with engine running and at operating temperature; add ATF+4 as needed to bring to proper level on dipstick (total capacity approximately 12 quarts).

Reassembly

1. All internal transmission components must be assembled in reverse order of disassembly with exact attention to thrust washer orientation and snap ring seating.
2. Every clutch pack clearance must be verified with feeler gauge and meet manufacturer specification before final assembly.
3. Torque converter must be fully seated in front pump before attempting to install transmission to engine. Verify depth measurement to ensure proper engagement.
4. All electrical connectors must click into place and be verified for proper seating to prevent shift quality issues or limp mode operation.
5. Transmission cooler lines must be torqued with line wrenches to prevent over-tightening and fitting damage.

Verification

• With engine running at idle in Park, verify no fluid leaks are present at pan, pump seal, output seal, cooler line fittings, or sensor locations.
• Verify transmission shifts smoothly through all gear ranges (P-R-N-D-3-2-1) with no harshness, slipping, or delayed engagement.
• Road test vehicle and verify smooth 1-2, 2-3, 3-4, and 4-5 upshifts under light throttle. Verify kickdown shifts occur properly under heavy throttle.
• Verify transmission fluid level is correct with engine at operating temperature and idling in Park. Fluid should be in crosshatch area of dipstick.
• Using scan tool, verify no transmission diagnostic trouble codes are present and all sensor readings are within normal range.
• Verify transmission fluid temperature reaches and maintains normal operating range (170-200°F) and cooler flow is adequate.
• After initial test drive, re-check all mounting bolts, cooler line fittings, and pan bolts for proper torque and verify no fluid leaks have developed.

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