Transmission Rebuild - Automatic

Complete disassembly, inspection, rebuild, and reinstallation of the Tremec TR-6060 6-speed automatic transmission in the 2008 Dodge Viper, including torque converter replacement, clutch pack servicing, and valve body overhaul.

Warnings

Tools required

Parts

• Automatic transmission master rebuild kit × 1 — Use OEM specification for TR-6060
• Torque converter × 1 — Inspect before ordering - replace if contaminated
• Transmission filter × 1 — Use OEM specification
• Front pump seal × 1 — Use OEM specification
• Rear output shaft seal × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Bellhousing to engine gasket × 1 — Use OEM specification
• Driveshaft support bearing (inspect) × 1 — Replace if worn
• Transmission mount × 1 — Inspect before ordering

Fluids

• Mopar ATF+4 automatic transmission fluid — 12 qt

Preparation

1. Verify the vehicle is equipped with an automatic transmission by inspecting the center console for automatic shifter
2. Raise vehicle on a lift to full working height and ensure secure engagement of lift arms
3. Disconnect negative battery cable and secure away from terminal
4. Remove engine cover by pulling upward on retaining clips
5. Remove rear wheels and set aside
6. Place drain pan with minimum 12-quart capacity under transmission pan
7. Mark driveshaft-to-differential flange orientation with paint pen for reinstallation alignment
8. Install engine support fixture across engine bay with chains or bars supporting engine from above, taking weight off motor mounts
9. Document all electrical connector orientations with photos before disconnection

Procedure

1. 1

   Drain transmission fluid and remove pan
   Loosen transmission pan bolts in a crisscross pattern, leaving two opposite corner bolts partially threaded. Allow fluid to drain as pan tilts. Once drained, remove remaining bolts and lower pan. NOT APPLICABLE: The TR-6060 manual transmission has no valve body or pan-mounted automatic filter. Do not attempt this step on the actual vehicle. Inspect fluid and filter for metal particles, clutch material, or burnt odor indicating internal damage severity. Note: Verify against manufacturer documentation - TR-6060 is a MANUAL transmission; no automatic rebuild kit exists for this unit.
2. 2

   Remove exhaust system components
   Disconnect oxygen sensors at electrical connectors near catalytic converters. Support exhaust system with adjustable stands. Remove the 4 bolts securing each catalytic converter to exhaust manifold flanges. Remove the 2 bolts at the mid-pipe connection joint. Lower exhaust system from vehicle and set aside. Inspect exhaust hangers for damage during removal.
3. 3

   Disconnect driveshaft
   Remove the 4 bolts securing the driveshaft to the rear differential flange. Wrap tape around u-joint caps to prevent loss. Support driveshaft; the 2008 Viper uses a single-piece driveshaft with no center support bearing - verify configuration before removal. Slide driveshaft rearward to disengage from transmission output shaft. Cap transmission output opening with clean shop towel to prevent fluid loss and contamination.
   ⚠Do not allow driveshaft to hang unsupported by the front u-joint as this will damage the joint.
4. 4

   Disconnect transmission electrical connections
   NOT APPLICABLE: The TR-6060 manual transmission has no transmission control module, range sensor, or solenoid pack. Disconnect only the reverse lockout solenoid connector and vehicle speed/reverse light switch connectors as equipped. Remove wire harness from retaining clips along transmission body.
5. 5

   Disconnect cooler lines and shifter linkage
   Place catch pan under cooler line connections. Using a flare nut wrench, disconnect the two transmission cooler hard lines from the transmission case fittings. Cap all open lines immediately. NOT APPLICABLE: The TR-6060 uses a direct top-mounted manual shifter. Remove the shifter boot and shifter assembly retaining bolts from inside the vehicle rather than a cable/bellcrank linkage.
6. 6

   Remove transmission crossmember
   Support transmission securely with transmission jack positioned at the pan rail area. Remove the 2 nuts securing the transmission mount to the crossmember. Remove the 4 bolts securing the crossmember to the chassis frame rails. Lower crossmember and remove from vehicle. Inspect transmission mount for cracking or separation; replace if damaged.
7. 7

   Remove starter and bellhousing inspection cover
   Remove the 3 bolts securing the starter motor to the bellhousing. Disconnect starter electrical connections and remove starter. Remove the 4 bolts securing the bellhousing dust cover/inspection plate. Mark torque converter to flexplate orientation with paint pen through the inspection opening for reinstallation reference.
8. 8

   Remove torque converter bolts
   NOT APPLICABLE: The manual TR-6060 uses a clutch assembly and flywheel, not a torque converter. There are no torque converter bolts. Push torque converter rearward toward transmission to disengage from flexplate. Verify torque converter moves freely and is not bound to flexplate.
9. 9

   Remove transmission to engine bolts and lower transmission
   Support transmission securely on transmission jack with safety chains. Remove the bellhousing-to-engine block bolts (verify exact count and pattern against 2008 Viper factory service manual before removal). Carefully pry transmission away from engine using pry points on bellhousing, not on pan or case. Once separated, pull transmission straight back approximately 2 inches to clear alignment dowels. While pulling back, hold torque converter in place to prevent it from falling. Lower transmission slowly and roll out from under vehicle. Place transmission on secure workbench.
   ⚠️Torque converter contains approximately 2 quarts of fluid and is not retained once transmission is separated. Secure it to prevent falling and causing injury.
10. 10

    Mount transmission and remove external components
    Mount transmission securely on rebuild stand with bellhousing facing down or at angle allowing fluid drainage. Remove the transmission range sensor from the case. Remove the speed sensors from the output housing. Remove the solenoid pack connector/wire harness from the case exterior. Remove any remaining external brackets, ground straps, or sensors and label for reinstallation.
11. 11

    Disassemble valve body assembly
    NOT APPLICABLE: The manual TR-6060 has no valve body. Disassembly involves removing the shift rail/detent assembly and case halves per manual transmission procedure. Carefully lower valve body assembly, keeping separator plate and gaskets aligned. Note position of manual valve engagement with range selector shaft. Remove separator plate and gaskets. Inspect all check balls in the case passages and note their positions and quantity before removal. Place valve body on clean workbench for further disassembly. Remove all solenoids from valve body by removing their retaining bolts. Disassemble valve body sections per rebuild kit instructions, noting spring positions and valve orientations.
12. 12

    Remove pump assembly
    NOT APPLICABLE: The manual TR-6060 has no hydraulic front pump assembly. Use slide hammer or pump puller to extract pump assembly from case bore. Remove pump gasket/seal from case. Mark pump gear orientation before disassembly. Disassemble pump by removing the bolts securing front and rear pump halves. Inspect pump gears for scoring or wear. Measure pump gear-to-housing clearance with feeler gauge; replace if clearance exceeds manufacturer specification. Replace front pump seal using appropriate seal driver.
13. 13

    Remove clutch pack assemblies and drums
    NOT APPLICABLE: The manual TR-6060 uses synchronizer assemblies, shift forks, and constant-mesh gear clusters on countershaft/mainshaft - not automatic clutch drums. As each drum is removed, note the number and arrangement of thrust washers and bearing races. Remove all snap rings securing clutch packs within each drum. Remove clutch plates in order - alternating steel and friction plates. Measure clutch pack clearance and individual plate thickness; replace worn plates. Inspect clutch drums for scoring or heat damage. Remove and replace all seals on clutch pistons using seal kit components.
14. 14

    Remove planetary gear sets
    NOT APPLICABLE: The manual TR-6060 uses constant-mesh helical gear sets on parallel shafts, not planetary gear sets. Remove rear planetary assembly and output shaft as a unit by pulling forward. Mark all gear mesh positions before separation. Inspect all planetary gears for chipped teeth or excessive wear. Check all bearings for roughness by hand rotation; replace as needed.
15. 15

    Remove output components and park mechanism
    With output shaft assembly removed from case, separate output shaft from rear planetary by removing retaining snap ring. Remove output shaft seal from case using seal puller. NOT APPLICABLE: The manual TR-6060 has no park pawl, park gear, or governor assembly. Check governor operation for binding.
16. 16

    Clean and inspect all components
    Clean all hard parts in approved transmission cleaning solvent tank. Blow dry with compressed air, ensuring all passages are clear. Inspect case for cracks, especially around bolt holes and bearing bores. Check all bearing bores for scoring. Inspect all shafts for wear in seal contact areas and bearing surfaces. Replace any components showing wear beyond service limits. Verify all new seals in rebuild kit match original components before discarding old parts.
17. 17

    Install park mechanism and output components
    Install new park pawl and spring into case. Install park pawl pivot pin, ensuring proper engagement. Install park pawl actuator rod, checking for smooth operation through full range. Install new output shaft seal using appropriately sized seal driver, ensuring seal is seated to proper depth. Lubricate seal lip with transmission assembly lube. Assemble output shaft to rear planetary using new snap ring. Install governor assembly on output shaft if equipped.
18. 18

    Assemble and install planetary gear sets
    Lubricate all thrust washers and bearing surfaces with transmission assembly lube. Install output shaft and rear planetary assembly into case, ensuring proper engagement with park gear. Install center support assembly and secure with snap ring, verifying full snap ring seating. Install front planetary gear set with correct thrust washers in noted positions. Install input sun gear shaft assembly. Install large snap ring retaining forward planetary assembly. NOT APPLICABLE: The manual TR-6060 has no planetary assemblies. Set bearing endplay/preload per manufacturer specification using selective shims.
19. 19

    Assemble clutch packs and install drums
    Install new seals on all clutch pistons using seal installation tools from rebuild kit. Lubricate all seals with transmission assembly lube. Install pistons into drums, ensuring seals are not damaged during installation. Install clutch return springs and retaining snap rings using spring compressor. Install clutch plates in correct order: steel plate, friction plate, alternating to specification. Install clutch pack retaining snap rings. Measure clutch pack clearance with feeler gauge; adjust with selective snap ring if needed to achieve specification. Install direct/overdrive clutch drum assembly into case. Install forward clutch drum assembly. Install input drum assembly and secure with retaining snap ring.
20. 20

    Assemble and install pump assembly
    Assemble pump gears into pump housing with noted orientation marks aligned. Install pump cover and secure with bolts in crisscross pattern. Verify pump rotates freely by hand. Install new front pump seal using seal driver. Install new pump gasket on transmission case. Lubricate pump seal with transmission assembly lube. Install pump assembly into case bore, ensuring proper engagement with input shaft splines. Rotate pump while installing to aid engagement. Install the 7 pump retaining bolts and tighten in star pattern.
21. 21

    Reassemble and install valve body
    Reassemble valve body sections per rebuild kit instructions, ensuring all valves move freely and springs are correctly positioned. Install all solenoids with new O-rings into valve body and secure with retaining bolts. Install check balls into case passages in noted positions and quantities (typically 4-6 check balls in various locations). Install new separator plate gaskets. Position separator plate, aligning all passages. Position valve body assembly, engaging manual valve with range selector shaft. Start all valve body bolts by hand, noting different bolt lengths in their original positions. NOT APPLICABLE: The manual TR-6060 has no valve body; torque all case and cover fasteners to manufacturer specification.
22. 22

    Install external components and prepare transmission
    Install transmission range sensor into case with new O-ring. Install speed sensors with new O-rings. Install solenoid pack connector/wire harness onto case exterior. Install any remaining external brackets, ground straps, or sensors using reference photos. Install new transmission filter, pressing firmly into valve body. Install new transmission pan gasket and install pan with bolts tightened in crisscross pattern. Remove transmission from rebuild stand.
23. 23

    Install torque converter
    Verify torque converter is clean and free of contamination. If original torque converter showed metal particles or burnt fluid, replace with new unit. Install new torque converter seal in pump if not already done. Lubricate converter hub and seal with transmission assembly lube. Install torque converter into pump, rotating to engage pump drive. NOT APPLICABLE: The manual TR-6060 has no torque converter. Fill the transmission with the specified manual transmission fluid per manufacturer specification.
24. 24

    Install transmission to engine
    Apply thin film of high-temp grease to torque converter hub. Position transmission on transmission jack and raise into position. Align transmission with engine, ensuring torque converter remains fully seated. Align dowel pins and mate bellhousing to engine block. Install the 6 bellhousing-to-engine bolts and tighten in star pattern. Rotate crankshaft to align torque converter bolt holes with flexplate using alignment marks made during disassembly. Install the 4 torque converter-to-flexplate bolts through bellhousing inspection opening, tightening in star pattern. Install bellhousing dust cover with its 4 bolts.
    ⚠If transmission does not mate easily to engine, do not force with bolts. Pull transmission back and verify torque converter is fully seated and input shaft is aligned with pilot bore.
25. 25

    Install starter and transmission crossmember
    Install starter motor with its 3 mounting bolts and reconnect electrical connections. Position transmission crossmember and install the 4 bolts securing it to chassis frame rails. Install the 2 nuts securing transmission mount to crossmember. Remove transmission jack. Remove engine support fixture from engine bay.
26. 26

    Reconnect shifter linkage and cooler lines
    Install bellcrank linkage bracket to transmission case with its 2 mounting bolts. Connect shifter cable end to ball socket on range lever. Install bolt securing shifter cable. Verify shifter cable is properly adjusted with engine off - selector should move through all gear positions with corresponding movement of range lever. Install both transmission cooler hard lines to case fittings using flare nut wrench. Tighten securely but do not overtighten.
27. 27

    Reconnect electrical connections
    Reconnect solenoid pack connector on driver side of case. Reconnect both speed sensor connectors on output housing. Reconnect transmission range sensor connector at shifter linkage. Reconnect main transmission control module connector on driver side of transmission case. Route wire harness through retaining clips along transmission body. Verify all connectors are fully seated with locking tabs engaged.
28. 28

    Install driveshaft
    Remove shop towel from transmission output shaft. Apply light coat of transmission assembly lube to output shaft splines. Support driveshaft and slide forward onto output shaft splines until fully seated. Install the 2 bolts securing center support bearing to chassis. Align driveshaft to rear differential flange using alignment marks made during disassembly. Install the 4 bolts securing driveshaft to differential flange and tighten in star pattern. Verify u-joint caps remain secured with tape until bolted.
29. 29

    Install exhaust system
    Raise exhaust system into position with adjustable stands. Install new gaskets at catalytic converter to exhaust manifold flanges. Install the 4 bolts at each catalytic converter flange connection. Install the 2 bolts at mid-pipe connection joint. Reconnect oxygen sensor electrical connectors. Remove exhaust support stands. Verify exhaust system has proper clearance from chassis and driveshaft throughout its length.
30. 30

    Fill transmission and perform initial checks
    Install rear wheels and torque to specification. Lower vehicle to ground. Reconnect negative battery cable. With vehicle level, remove the fill plug on the side of the transmission case and add the manufacturer-specified quantity (approximately 2.5-3 quarts) of the correct manual transmission fluid until it reaches the bottom of the fill plug hole. Reinstall fill plug and torque to specification. Check fluid level with engine running at idle and transmission in Park at normal operating temperature. Add fluid as needed to bring level to cold mark. Recheck after test drive and adjust to hot full mark.

Reassembly

1. Torque all fasteners to proper specifications when manufacturer data becomes available
2. Fill transmission with Mopar ATF+4 fluid only - do not substitute other ATF types
3. All seals and gaskets from rebuild kit must be replaced even if original parts appear serviceable
4. Verify torque converter is fully seated before installing transmission to engine - should be approximately 1-1/8 inch from bellhousing face to converter boss
5. Check all electrical connectors for proper seating with locking tabs engaged
6. Adjust shifter cable if needed to ensure proper gear selection through all ranges

Verification

• With engine running at idle in Park, verify no transmission fluid leaks at pan, pump, cooler lines, or seals
• Perform test drive: verify smooth engagement in all forward gears and reverse with no slipping, harsh shifts, or abnormal noises
• Verify transmission shifts through all gears at appropriate vehicle speeds under normal acceleration
• Check for proper kickdown operation under wide-open throttle acceleration
• Verify Park pawl holds vehicle on incline with engine off
• Recheck fluid level at operating temperature after test drive - should be at hot full mark
• Scan for diagnostic trouble codes using appropriate scan tool - no transmission-related codes should be present
• After 500 miles of operation, recheck fluid level and inspect for leaks, particularly at pump seal and output shaft seal

Related trouble codes on this vehicle

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

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle