Transmission Output Shaft Bearing

This procedure replaces the output shaft bearing on the Tremec T56 6-speed manual transmission in a 2005 Dodge Viper, requiring transmission removal, disassembly of the rear extension housing, and bearing replacement.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification or Timken bearing equivalent
• Transmission rear extension housing gasket × 1 — Use OEM specification
• Transmission output shaft seal × 1 — Use OEM specification
• RTV gasket maker (high-temp, anaerobic) × 1 — Permatex Ultra Black or equivalent
• Clutch release bearing × 1 — Use OEM specification - inspect and replace if worn
• Pilot bearing × 1 — Use OEM specification - inspect and replace if worn
• Transmission mounting hardware kit × 1 — Various mounting bolts - use OEM specification

Fluids

• 75W-90 synthetic GL-4 — 4 qt

Preparation

1. Position vehicle on level ground and engage parking brake.
2. Disconnect negative battery cable to prevent starter engagement during transmission removal.
3. Allow exhaust system to cool completely if vehicle has been recently driven (minimum 2 hours).
4. Raise vehicle on lift or jack stands to working height - you will need access to the entire underside of the vehicle from front cross-member to rear differential.
5. Remove both rear wheels to provide working clearance around rear suspension and exhaust.
6. Place drain pan under transmission and drain gear oil by removing drain plug from transmission case.
7. Gather all tools and parts before beginning - this is a long procedure and interruptions increase the risk of contamination.

Procedure

1. 1

   Remove exhaust system components
   Disconnect exhaust at the collector flanges behind the catalytic converters. Remove the complete exhaust system from the catalytic converters rearward by unbolting all hangers and support brackets. The Viper side-exit exhaust must be completely removed to access the transmission. Support the exhaust as you remove hangers to prevent damage to components.
2. 2

   Mark and remove driveshaft
   Mark the driveshaft-to-differential flange orientation with paint or a scribe to ensure proper phasing on reinstallation. Remove the 4 bolts securing the driveshaft to the rear differential companion flange. Support the driveshaft and slide it rearward out of the transmission output shaft. Inspect the slip yoke for scoring or wear. Place a plastic bag over the transmission extension housing to prevent fluid leakage and contamination entry.
3. 3

   Disconnect shift linkage and electrical connections
   Remove the shift linkage by disconnecting the linkage rod from the transmission shift tower. This typically involves removing a roll pin or bolt at the shift arm. Disconnect the reverse light switch electrical connector and the vehicle speed sensor connector at the transmission case. Tag all connectors to ensure correct reinstallation.
4. 4

   Support engine and remove crossmember
   Position a floor jack with a block of wood under the engine oil pan to support engine weight - do not place jack directly on aluminum oil pan. Remove the transmission crossmember mounting bolts (bolt count per factory service manual for this chassis). Lower and remove the crossmember from the vehicle. The transmission will now be supported only by its bellhousing connection to the engine.
5. 5

   Position transmission jack and remove starter
   Position the transmission jack under the transmission case and secure with safety straps. The transmission weighs approximately 135 pounds and is awkward to handle. Remove the starter motor by disconnecting electrical connections and removing the mounting bolts. The starter must be removed to access upper bellhousing bolts.
6. 6

   Disconnect hydraulic clutch line
   Disconnect the hydraulic clutch line from the slave cylinder at the bellhousing. The Viper uses an internal slave cylinder (concentric slave cylinder). There will be some fluid loss - cap the line to prevent further fluid loss and contamination. Do not depress the clutch pedal with the line disconnected or the system will require bleeding.
7. 7

   Remove bellhousing bolts and separate transmission
   Remove all bellhousing-to-engine block bolts. Remove all bellhousing-to-engine block bolts (verify exact count and bolt lengths against factory service documentation for this application). Note bolt length and position as some bolts may be different lengths. With the transmission securely supported on the transmission jack, carefully pull the transmission straight back away from the engine. The input shaft must clear the clutch disc and pilot bearing - if binding occurs, check that all mounting bolts are removed and reposition the transmission jack angle slightly. Once the input shaft clears the bellhousing, lower the transmission and remove from under the vehicle.
8. 8

   Disassemble transmission rear extension housing
   With the transmission on a clean workbench, remove the rear extension housing bolts securing the housing to the main case. Remove the rear extension housing bolts securing the housing to the main case (verify exact count against factory service documentation). Carefully separate the extension housing by pulling it straight back off the output shaft. The housing contains the output shaft seal and rear bushing. Inspect the housing for cracks or damage.
9. 9

   Remove output shaft assembly
   With the extension housing removed, the output shaft and gear assembly is now accessible. Remove the snap ring retaining the output shaft bearing in the case. Note the orientation and position of all shims and spacers - these control endplay and must be reinstalled in the same locations. Carefully pull the output shaft assembly rearward out of the main case. If the shaft is tight, use a soft mallet to tap on the end of the shaft while pulling - do not damage the shaft threads or splines.
10. 10

    Remove failed output shaft bearing
    With the output shaft removed from the case, the bearing race that remains in the case must be removed. Use a bearing puller or slide hammer with internal puller attachment to extract the outer bearing race from the transmission case bore. If the bearing is severely damaged, the race may come out in pieces - ensure all pieces are removed. Clean the bearing bore in the transmission case thoroughly with solvent and inspect for scoring, cracks, or damage. The bore must be smooth and free of burrs for the new bearing to seat properly.
11. 11

    Remove bearing from output shaft
    The bearing inner race and roller assembly must be removed from the output shaft. Use a bearing puller to remove the bearing from the shaft. Position the puller jaws behind the bearing inner race and apply pressure evenly. If using a press, support the shaft on press blocks and press the bearing off. Inspect the output shaft bearing surface for scoring, discoloration, or damage. If the shaft is damaged, it must be replaced - do not reuse a damaged shaft as it will destroy the new bearing.
12. 12

    Install new bearing on output shaft
    Clean the output shaft bearing surface with solvent and dry completely. Place the new bearing on the shaft with the correct orientation - the bearing cage typically faces the gear side of the shaft. Using a press or bearing driver that contacts only the inner bearing race, press the bearing onto the shaft until it seats against the shaft shoulder. Do not press on the outer race or rollers as this will damage the bearing. Verify the bearing is fully seated and rotates smoothly by hand.
13. 13

    Install bearing outer race in transmission case
    Clean the transmission case bearing bore thoroughly. Place the new bearing outer race in the bore and verify it is square to the bore. Using a bearing driver or large socket that contacts only the outer edge of the race, drive or press the race into the case until it is fully seated. The race must be installed squarely - any cocking or misalignment will cause premature bearing failure. Verify the race is fully seated by checking that it is flush with or slightly below the case shoulder.
14. 14

    Reinstall output shaft assembly
    Lubricate the new bearing with transmission gear oil. Carefully slide the output shaft assembly back into the transmission case, guiding the bearing into the race in the case bore. The shaft should slide in smoothly - if binding occurs, verify the bearing and race are properly aligned. Reinstall all shims and spacers in their original positions. Install the snap ring to retain the bearing in the case, ensuring the snap ring is fully seated in its groove.
15. 15

    Install new extension housing gasket and seal
    Clean all gasket material from the extension housing and transmission case mating surfaces using a plastic gasket scraper. Install a new output shaft seal in the extension housing by driving it in with a seal driver until flush with the housing face. Apply a thin bead of the specified sealer to the extension housing mating surface or install the new gasket per manufacturer instructions, using the sealer type specified in the factory service manual. Carefully slide the extension housing onto the output shaft, ensuring the seal does not roll or damage. Install and torque the extension housing bolts in a crisscross pattern.
16. 16

    Inspect and prepare clutch components
    With the transmission removed, inspect the clutch disc, pressure plate, flywheel, and release bearing. If the output shaft bearing failed due to misalignment or excessive load, inspect the clutch for signs of abuse or improper installation. Replace the release bearing and pilot bearing as preventative maintenance. Clean the flywheel and pressure plate friction surfaces with brake cleaner. Verify flywheel bolts are torqued to specification if disturbed.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
17. 17

    Reinstall transmission to engine
    Apply a small amount of high-temp grease to the input shaft splines and pilot bearing. Position the transmission on the transmission jack and raise into position. Use a clutch alignment tool if the clutch was disturbed to ensure the disc is centered. Carefully guide the input shaft through the clutch disc and into the pilot bearing while aligning the bellhousing to the engine block. The transmission should slide forward smoothly - if binding occurs, rotate the output shaft slightly to align splines. Do not force the transmission forward or use bellhousing bolts to pull it into place. Once the bellhousing is flush with the engine block, install all bellhousing bolts and torque to specification.
18. 18

    Reconnect hydraulic clutch and install starter
    Reconnect the hydraulic clutch line to the internal slave cylinder. The system may require bleeding if air entered during disconnection. Reinstall the starter motor and torque mounting bolts to specification. Reconnect all starter electrical connections.
19. 19

    Install crossmember and lower engine support
    Raise the transmission slightly with the transmission jack to align with crossmember mounting holes. Install the crossmember and torque mounting bolts to specification. Remove the floor jack from under the engine oil pan. Verify the transmission is properly supported by the crossmember before removing the transmission jack.
20. 20

    Reconnect shift linkage, electrical, and driveshaft
    Reconnect the shift linkage to the transmission shift tower, ensuring proper engagement and installing any roll pins or bolts. Reconnect all electrical connectors (reverse light switch, vehicle speed sensor). Remove the plastic bag from the transmission output shaft. Slide the driveshaft forward onto the output shaft, aligning the marks made during disassembly. Install the driveshaft-to-differential flange bolts and torque to specification in a crisscross pattern. Note: Remove the bolts securing the driveshaft to the rear differential companion flange (verify exact count against factory documentation).
21. 21

    Reinstall exhaust system
    Reinstall the complete exhaust system by reversing the removal procedure. Install all hangers and support brackets. Reconnect the exhaust at the collector flanges and torque mounting hardware. Verify the exhaust has adequate clearance from the driveshaft, chassis, and body components throughout its length.
22. 22

    Fill transmission and perform final checks
    Fill the transmission with the factory-specified fluid (the Tremec T56 in this application typically uses ATF or a Tremec-approved synthetic manual transmission fluid, not gear oil), approximately 4.0 quarts, through the fill plug opening on the side of the transmission case. The transmission is full when oil begins to drip from the fill hole with the vehicle level. Install the fill plug and torque to specification. Reinstall rear wheels and torque lug nuts. Lower vehicle to the ground. Reconnect the battery negative cable.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)

Reassembly

1. Reassembly is detailed in the installation steps above.
2. Ensure all fasteners are torqued to specification using a calibrated torque wrench.
3. Apply thread locker to fasteners as specified in the procedure.
4. Bleed the hydraulic clutch system if air entered during the hydraulic line disconnection.
5. Double-check that all electrical connectors are fully seated and secured.

Verification

• Start the engine and verify no unusual noises from the transmission or clutch area.
• With the engine running and clutch pedal depressed, shift through all gears to verify proper engagement. Each gear should engage smoothly without grinding.
• Test drive the vehicle at various speeds and loads. Listen for any bearing noise, whining, or grinding from the transmission.
• After the first 50 miles, recheck the transmission fluid level and inspect for leaks at the extension housing, bellhousing, and all connection points.
• Verify proper shift linkage adjustment - all gears should be easy to select and should not pop out of gear under load.
• Check underneath the vehicle for any exhaust leaks, fluid leaks, or loose fasteners after the test drive.

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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