Transmission R&R - Manual

Remove and replace the manual transmission (Tremec T56) on a 2005 Dodge Viper 8.3L V10, including driveshaft, clutch hydraulics, shifter mechanism, and bellhousing separation.

Warnings

Tools required

Parts

• Transmission fluid (75W-90 synthetic GL-4) × 1 — Use OEM specification
• Clutch hydraulic fluid (DOT 4) × 1 — Use OEM specification
• Driveshaft U-joint strap bolts (if reusing) × 4 — Use OEM or grade 8 replacement
• Transmission mount (if worn) × 1 — OEM or equivalent
• Bellhousing gasket or sealant × 1 — Use OEM gasket or RTV
• Clutch slave cylinder (if faulty) × 1 — Internal concentric slave cylinder

Fluids

• 75W-90 synthetic GL-4 manual transmission fluid — 4 qt
• DOT 4 brake/clutch fluid — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Disconnect negative battery cable to prevent electrical shorts.
3. Raise vehicle on lift or securely support on jack stands at all four corners, allowing sufficient clearance for transmission removal from underneath.
4. Remove exhaust system from catalytic converters back to allow transmission clearance. This typically requires removing exhaust hangers and separating flanges at collector.
5. Place drain pan under transmission and remove drain plug to drain transmission fluid. Reinstall drain plug after draining.
6. Mark driveshaft and differential companion flange orientation with paint or punch marks for proper reinstallation alignment.

Procedure

1. 1

   Remove driveshaft
   Remove the 4 bolts securing the driveshaft to the rear differential companion flange. Support driveshaft and slide it rearward to disengage from transmission output shaft. Remove driveshaft from vehicle. Inspect transmission output shaft seal for leakage; replace if needed during reinstallation.
2. 2

   Disconnect shifter mechanism
   Working from inside the vehicle, remove the shift knob by unthreading counterclockwise. Remove the shift boot retaining ring and slide boot up the shifter. From underneath vehicle, disconnect the shift linkage at the transmission by removing the pivot bolt and clevis pin connecting the shifter to the transmission shift tower. Some models may have a direct-mount shifter requiring removal of 4 bolts securing the shifter housing to the transmission. Mark shifter orientation before removal.
3. 3

   Disconnect clutch hydraulic line
   Locate the clutch hydraulic line connection at the bellhousing where it connects to the internal concentric slave cylinder. Using a line wrench, carefully disconnect the hydraulic line fitting. Expect some fluid spillage; have rags ready. Cap or plug the hydraulic line to prevent further fluid loss and contamination. Do not allow brake fluid to contact painted surfaces.
4. 4

   Disconnect electrical connections
   Disconnect the reverse light switch connector on the driver side of the transmission case. Disconnect the output/vehicle speed sensor connector if equipped on the transmission (verify sensor type and location against the 2005 Viper service manual). On some models, disconnect the skip-shift solenoid connector if equipped. Press release tabs and carefully pull connectors free.
5. 5

   Remove transmission crossmember and mount
   Position transmission jack under transmission to support weight. Remove the 2 bolts securing the transmission mount to the crossmember. Remove the 4 bolts securing the crossmember to the frame rails. Lower transmission jack slightly and remove crossmember from vehicle. Inspect transmission mount for deterioration; replace if cracked or oil-soaked.
6. 6

   Remove starter motor
   Locate the starter motor on the passenger side of the bellhousing. Disconnect the starter motor electrical connections (battery cable and trigger wire). Remove the 2 bolts securing the starter to the bellhousing and remove starter from vehicle. This provides access to lower bellhousing bolts and prevents damage during transmission removal.
7. 7

   Remove bellhousing-to-engine bolts
   Remove all bellhousing-to-engine block mounting bolts. Remove all bellhousing-to-engine block mounting bolts around the perimeter of the bellhousing (verify exact count and locations against the 2005 Viper service manual). Access upper bolts from above engine bay; access lower bolts from underneath. Note bolt lengths and locations as they may vary. Keep bolts organized for reinstallation.
8. 8

   Separate transmission from engine
   With transmission jack supporting full weight of transmission, carefully pull transmission straight back away from engine. The input shaft must slide out of the clutch disc and pilot bearing without binding. If resistance is encountered, stop and verify all mounting bolts are removed and transmission is properly aligned. Once input shaft clears clutch, carefully lower transmission on jack and roll out from under vehicle. Use extreme caution with weight distribution.
9. 9

   Inspect clutch components
   With transmission removed, inspect clutch disc, pressure plate, flywheel surface, pilot bearing, and concentric slave cylinder release bearing. Check flywheel for heat checking, cracks, or excessive wear. If clutch replacement is needed, remove pressure plate bolts in star pattern to prevent warping, then remove clutch disc. This is the ideal time to replace clutch components if showing wear.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)
10. 10

    Prepare transmission for installation
    If installing a replacement transmission, transfer any necessary components from old unit (sensors, switches, crossmember mount, etc.). Clean bellhousing mating surface on both transmission and engine block. Apply thin bead of RTV sealant to bellhousing mating surface if no gasket is used, or install new gasket per factory specification. Verify input shaft splines are clean and lightly lubricate with high-temp grease.
11. 11

    Install transmission to engine
    Position transmission on transmission jack and raise into position under vehicle. Insert input shaft through clutch disc, using clutch alignment tool if necessary to center disc. Carefully push transmission forward, ensuring input shaft engages pilot bearing and slides through clutch disc splines. Do not force—if binding occurs, lower slightly and realign. Once bellhousing is flush with engine block, install all bellhousing-to-engine bolts and torque to specification in star pattern.
12. 12

    Install crossmember and transmission mount
    Raise transmission jack to align transmission mount with crossmember position. Install crossmember to frame rails and torque bolts to specification. Install transmission mount-to-crossmember bolts and torque to specification. Remove transmission jack once crossmember is secured.
13. 13

    Reconnect all connections and components
    Reinstall starter motor to bellhousing and torque bolts to specification. Reconnect starter electrical connections. Reconnect all electrical connectors (reverse light switch, VSS, skip-shift solenoid if equipped). Reconnect clutch hydraulic line to concentric slave cylinder and tighten fitting with line wrench—do not overtighten. Reconnect shifter mechanism to transmission, ensuring proper alignment with marks made during removal.
14. 14

    Install driveshaft
    Apply light coating of grease to transmission output shaft splines. Slide driveshaft forward onto output shaft, ensuring splines engage fully. Align marks made during removal and install driveshaft to differential companion flange. Install all 4 bolts and torque evenly in cross pattern to prevent flange distortion.
15. 15

    Refill transmission and bleed clutch system
    Fill transmission through fill plug opening with the factory-specified manual transmission fluid until fluid reaches bottom of fill hole (verify exact fluid type and capacity against the 2005 Viper service manual before filling). Install fill plug and torque to specification. Bleed clutch hydraulic system at bleeder valve on concentric slave cylinder until firm pedal is achieved and no air bubbles are present. Top off clutch fluid reservoir with DOT 4 fluid. Reinstall exhaust system and reconnect battery.

Reassembly

1. Torque all fasteners to specification in proper sequence as noted in steps.
2. Ensure all electrical connectors are fully seated with locking tabs engaged.
3. Verify driveshaft alignment marks match before final torque.
4. Double-check that no tools or rags are left in engine bay or under vehicle before lowering.

Verification

• With engine off, depress clutch pedal and verify firm resistance with no sponginess (indicates proper hydraulic bleeding).
• Start engine and verify reverse lights illuminate when transmission is in reverse.
• With engine running and clutch depressed, shift through all gears to verify smooth engagement without grinding.
• Test drive vehicle through all gears, verifying smooth shifts under light and heavy acceleration.
• Inspect under vehicle for any fluid leaks from transmission, clutch hydraulic line, or driveshaft connection after test drive.
• Verify no abnormal noises from transmission during operation and that shifter returns to neutral properly.

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