Shift Solenoids - All

Replace all shift solenoids in the 2005 Dodge Viper's TR-6060 6-speed manual transmission by removing the transmission pan and valve body to access solenoid pack.

Warnings

Tools required

Parts

• Shift solenoid assembly/pack (complete set) × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Valve body gasket (if disturbed) × 1 — Use OEM specification
• Transmission fluid filter (recommended) × 1 — Use OEM specification

Fluids

• 75W-90 synthetic GL-4 — 4.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake firmly.
2. Disconnect negative battery terminal to prevent electrical faults during solenoid replacement.
3. Raise vehicle using floor jack at factory jacking points and support securely on jack stands at frame rails. Vehicle should be level front-to-back.
4. Allow transmission to cool completely if vehicle was recently driven (minimum 2 hours).
5. Position transmission drain pan directly under transmission pan. Wear nitrile gloves and safety glasses.

Procedure

1. 1

   Drain transmission fluid
   Locate the transmission drain plug on the bottom of the transmission pan (passenger side, rear corner). Using a 13mm socket, slowly loosen the drain plug while supporting it with your hand. Once loose, quickly remove the plug and allow fluid to drain completely into the pan. This will take 5-10 minutes. Inspect the drained fluid for metal particles or burnt smell indicating internal transmission damage. Install drain plug with new crush washer if equipped.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Remove transmission pan bolts
   Locate all transmission pan bolts around the perimeter of the pan (approximately 17-19 bolts depending on pan configuration). Using a 10mm socket, loosen all bolts in a criss-cross pattern working from the outside toward the center. Leave two bolts at opposite corners loosely threaded. Carefully pry the pan down at one corner to break the gasket seal and allow remaining fluid to drain. Once drained, remove the final two bolts and lower the pan. Expect additional fluid spillage.
   ⚠Even after draining the plug, 1-2 quarts of fluid remain trapped above the pan. Break the seal slowly at one corner to control spillage.
   Torque spec

   Transmission Pan Bolts12 Nm (9 lb-ft)
3. 3

   Clean pan and inspect filter
   Set the pan aside on a clean work surface. Inspect the transmission filter (located inside the transmission, visible once pan is removed). Check for debris or metal particles caught in the filter screen. Remove the filter by pulling straight down (it may be press-fit or have 2-3 retaining bolts). Clean the pan thoroughly with brake cleaner, removing all old gasket material with a plastic scraper. Inspect the magnet in the pan for metal shavings (small amount is normal; excessive metal indicates wear).
4. 4

   Locate valve body and solenoid assembly
   The skip-shift (CAGS) solenoid is mounted externally on the transmission case, not inside the transmission. Locate the solenoid on the transmission housing, identifiable by its electrical connector and threaded body. The reverse lockout solenoid is similarly mounted externally on the case.
5. 5

   Disconnect solenoid electrical connector
   Locate the electrical connector for the shift solenoid. Press the retaining tab on the connector and pull straight away from the solenoid to disconnect. Note the connector orientation and routing of the wire harness for reinstallation. Inspect the connector pins for corrosion or damage.
6. 6

   Remove solenoid mounting hardware
   The shift solenoid is secured to the valve body with 2 mounting bolts (typically 10mm hex head). Using a socket with extension, remove these bolts completely. Keep bolts in a clean container. Note the exact position and orientation of the solenoid for proper installation of the replacement unit.
7. 7

   Remove old solenoid assembly
   Carefully pull the solenoid assembly straight out from the valve body. It may be sealed with an O-ring and require slight twisting or gentle prying. Do not damage the valve body bore. Once removed, inspect the O-ring seals on the old solenoid and the mating surface in the valve body for damage or debris.
8. 8

   Prepare new solenoid for installation
   Remove the new solenoid assembly from its packaging. Verify it matches the old unit in physical dimensions, connector type, and mounting hole locations. Lubricate any O-rings on the new solenoid with clean, correct-specification transmission fluid (per the factory service manual for this T56 application) to ease installation and prevent seal damage. Do not use petroleum-based lubricants.
9. 9

   Install new solenoid assembly
   Align the new solenoid with the valve body bore, ensuring proper orientation (connector facing outward toward transmission case opening). Push the solenoid firmly into the bore until it seats completely against the valve body. The mounting bolt holes should align perfectly. Install the 2 mounting bolts finger-tight, then torque in a cross pattern to specification.
10. 10

    Reconnect electrical connector
    Route the solenoid wiring harness to match the original path. Push the electrical connector onto the solenoid until the retaining tab clicks into place. Gently tug on the connector to verify it is fully seated and locked.
11. 11

    Install new filter and prepare for pan installation
    Install the new transmission filter by aligning it with the filter mounting location and pushing upward until it seats (or secure with mounting bolts if equipped). Wipe the transmission case pan sealing surface clean with brake cleaner and a lint-free rag. Ensure no gasket material remains and the surface is completely dry.
12. 12

    Install pan with new gasket
    Position the new transmission pan gasket onto the pan, aligning all bolt holes. Some gaskets are adhesive-backed; others require careful alignment during installation. Lift the pan into position against the transmission case, ensuring the gasket stays aligned. Start all pan bolts by hand, threading them 2-3 turns to hold the pan in place. Once all bolts are started, tighten in a criss-cross pattern from the center outward to specification.
    Torque spec

    Transmission Pan Bolts12 Nm (9 lb-ft)
13. 13

    Refill transmission with fluid
    Locate the transmission fill plug on the side of the transmission case. Remove the fill plug. Verify the correct fluid specification for the Viper T56 in the factory service manual (this application typically specifies an ATF-type manual transmission fluid, not GL-4 gear oil). Add fluid through the fill hole until it begins to drip from the fill hole, then reinstall and torque the fill plug to the FSM-specified value.ug and torque to 22 ft-lb. Note: Reinstall fill plug and torque to the value specified in the factory service manual for this T56 application.
14. 14

    Reconnect battery and clear codes
    Reconnect the negative battery terminal. If the vehicle stored any CAGS/skip-shift related fault codes, clear them using an OBD-II scanner via the PCM. Note that this is a manual transmission with no transmission control module. If no scanner is available, codes may clear after several successful drive cycles.

Reassembly

1. Verify all pan bolts are torqued to specification in criss-cross pattern.
2. Confirm drain plug and fill plug are both installed and torqued properly.
3. Double-check electrical connector is fully seated and locked on solenoid.
4. Wipe down all exterior transmission surfaces to identify any new fluid leaks during test drive.

Verification

• Lower vehicle from jack stands and start engine. Allow to idle for 2-3 minutes while monitoring for fluid leaks around the transmission pan and drain plug.
• With engine running, shift through all gears (clutch depressed) to circulate fluid through the transmission. Check fluid level at fill plug again; top off if necessary.
• Test drive vehicle under normal conditions. The skip-shift function (if equipped) should engage smoothly during 1st to 4th gear transitions under light throttle at 15-20 mph. No warning lights should illuminate.
• After test drive, re-inspect transmission pan and drain plug for leaks. Re-check fluid level when transmission is at operating temperature (150-180°F).
• If skip-shift warning light remains illuminated or transmission exhibits shifting issues, use an OBD-II scanner to read transmission control module codes for proper solenoid operation diagnostics.

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