Flywheel

Complete removal and replacement of the manual transmission flywheel on a 2008 Dodge Viper 8.4L V10, requiring transmission removal and clutch assembly access.

Warnings

Tools required

Parts

• Flywheel (if damaged or resurfacing not possible) × 1 — Use OEM specification
• Clutch disc × 1 — Use OEM specification or performance equivalent
• Pressure plate × 1 — Use OEM specification or performance equivalent
• Pilot bearing × 1 — Use OEM specification
• Flywheel bolts (TTY - do not reuse) × 8 — Use OEM specification
• Transmission fluid (if replacing) × 1 — Pennzoil Synchromesh 75W-90

Fluids

• transmission_manual — 4.2 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and secure away from battery terminal
3. Allow exhaust system to cool completely if vehicle has been running
4. Raise vehicle on lift or with floor jack and support securely on jack stands at all four corners at manufacturer-recommended lift points
5. Remove both rear wheels to improve access and reduce weight on jack stands
6. Place transmission drain pan under transmission
7. Drain transmission fluid by removing fill and drain plugs from transmission case

Procedure

1. 1

   Remove exhaust system components
   Disconnect exhaust system from headers. Remove exhaust hangers supporting the mid-pipes and rear mufflers. The Viper exhaust typically has slip-fit connections at the collector flanges - loosen clamps and separate exhaust from headers. Support exhaust components and remove completely or secure out of the way to provide transmission clearance. Disconnect oxygen sensors if they will interfere with exhaust removal.
2. 2

   Disconnect driveshaft
   Mark the driveshaft-to-differential flange orientation for proper reinstallation. Remove the four bolts securing the driveshaft to the rear differential pinion flange. Carefully slide the driveshaft rearward to disengage the front slip yoke from the transmission output shaft. Support the driveshaft and remove it from under the vehicle. Inspect the slip yoke for damage and the transmission output seal for leaks.
3. 3

   Remove transmission crossmember
   Place the transmission jack under the transmission case to support its weight. Remove the two bolts securing the transmission mount to the crossmember. Remove the crossmember mounting bolts (typically four bolts securing crossmember to frame rails). Carefully lower the transmission jack slightly and remove the crossmember from the vehicle.
4. 4

   Disconnect shift linkage and electrical connections
   Disconnect the shift linkage from the transmission. The TR6060 uses a rod-type shifter mechanism - remove the retaining clips and disconnect the shift rods from the transmission shift arms. Disconnect the reverse light switch electrical connector on the driver side of the transmission. Disconnect the speed sensor connector if equipped. Label all connections for proper reassembly.
5. 5

   Disconnect clutch hydraulic line
   Locate the clutch slave cylinder on the driver side of the bellhousing. Disconnect the hydraulic line from the slave cylinder by removing the retaining clip or threaded fitting. Be prepared for minor fluid spillage. Cap or plug the hydraulic line to prevent contamination and fluid loss. The slave cylinder will remain attached to the transmission during removal.
6. 6

   Remove bellhousing and transmission mounting bolts
   Locate and remove all bellhousing-to-engine block bolts. The TR6060 transmission uses 6-8 bolts of varying lengths around the bellhousing perimeter. Note the location of each bolt length for proper reinstallation. Check for any ground straps or wiring harness brackets secured by these bolts and remove them. Ensure the transmission is properly supported on the transmission jack before removing the final bolts.
7. 7

   Remove transmission assembly
   With all bolts removed and transmission supported on the jack, carefully slide the transmission straight back from the engine. Maintain alignment to prevent damage to the clutch disc or input shaft. The input shaft must clear the pilot bearing and clutch disc splines. Once clear of the engine, carefully lower the transmission and roll it out from under the vehicle. The transmission weighs approximately 130 lbs - use proper lifting technique or additional assistance.
8. 8

   Remove pressure plate and clutch disc
   With the transmission removed, the clutch assembly is now accessible. Insert the clutch alignment tool through the clutch disc to support it during pressure plate removal. Using a crisscross pattern, gradually loosen the six pressure plate bolts in multiple passes to relieve spring tension evenly. Remove all bolts and carefully remove the pressure plate, then remove the clutch disc. Inspect both components for wear, hot spots, or damage.
9. 9

   Lock flywheel and remove flywheel bolts
   Install the flywheel holding tool to prevent crankshaft rotation. The Viper V10 flywheel is secured by flywheel bolts around its perimeter (verify exact count and pattern against 2008 Viper factory service manual before ordering bolts). Using a breaker bar or impact wrench, remove all eight flywheel bolts. These are torque-to-yield bolts and must not be reused. Remove the bolts completely and set aside for disposal.
10. 10

    Remove flywheel from crankshaft
    With all bolts removed, carefully pull the flywheel straight off the crankshaft flange. The flywheel is located by dowel pins on the crankshaft flange. If the flywheel is stuck, use a soft pry bar at the appropriate pry points - never pry against the friction surface. The flywheel is heavy (approximately 30-40 lbs) - support it properly during removal. Once removed, inspect the crankshaft flange for damage and clean the mating surface thoroughly.
11. 11

    Inspect and prepare replacement flywheel
    If installing a new flywheel, verify it is the correct part for the 8.4L V10 application. If reusing the original flywheel, verify it has been inspected and resurfaced by a qualified machine shop (warpage must be within 0.010 inch, no cracks or heat damage). Clean the flywheel mounting surface with brake cleaner. Inspect the pilot bearing in the end of the crankshaft and replace if worn or noisy. Clean the crankshaft flange thoroughly with brake cleaner and ensure dowel pins are present and undamaged.
12. 12

    Install flywheel and torque bolts
    Align the flywheel with the dowel pins on the crankshaft flange and install it onto the crankshaft. Install new TTY flywheel bolts per the factory service manual (verify exact count). Apply thread locking compound only if specified by the OEM procedure — many TTY bolts are pre-coated and must not have additional compound added. Hand-tighten all bolts first. Using the flywheel holding tool to prevent rotation, torque all eight bolts to specification in a star pattern across opposing bolts. Torque the new TTY flywheel bolts in the specified sequence per the 2008 Viper factory service manual (verify exact multi-stage torque and any torque-angle values before final tightening). Verify all bolts are properly torqued.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
13. 13

    Install new clutch assembly
    Install the new clutch disc onto the flywheel with the cushioned side (damper springs) facing the pressure plate direction. The disc will be marked 'Flywheel Side' or similar. Insert the clutch alignment tool through the clutch disc and into the pilot bearing to hold the disc centered. Position the new pressure plate over the clutch disc and align the dowel pins or bolt holes. Install the six pressure plate bolts and tighten in a crisscross pattern gradually in multiple passes to avoid warping the pressure plate. Torque the pressure plate bolts to the specification listed in the 2008 Viper factory service manual or the pressure plate manufacturer's instructions (verify exact torque before final tightening). Remove the clutch alignment tool only after the transmission is ready to install.
14. 14

    Install transmission assembly
    Apply a light coating of high-temperature grease to the input shaft splines. Ensure the clutch alignment tool is still in place. Position the transmission on the transmission jack and carefully raise it into position behind the engine. Align the input shaft with the clutch disc splines (the alignment tool will guide it). Carefully slide the transmission forward onto the engine, ensuring the input shaft engages the pilot bearing and the bellhousing mates flush with the engine block. Do not force it - if binding occurs, check alignment. Once the bellhousing is within 1/4 inch of the block, the clutch disc should be properly engaged.
15. 15

    Install bellhousing bolts and reconnect components
    Install all bellhousing-to-engine block bolts in their correct locations (note the different bolt lengths documented during removal). Tighten the bolts in a crisscross pattern to ensure even seating. Torque all bellhousing-to-engine block bolts to the values specified in the 2008 Viper factory service manual (verify exact torque per bolt location/size before tightening). Reinstall any ground straps or brackets. Reconnect the clutch hydraulic line to the slave cylinder and secure with the retaining clip or threaded fitting. Reconnect the reverse light switch and speed sensor electrical connectors. Reconnect the shift linkage to the transmission shift arms and install retaining clips.
16. 16

    Reinstall crossmember and driveshaft
    Raise the transmission slightly with the transmission jack. Position the crossmember and install the four mounting bolts securing it to the frame rails. Install the two transmission mount-to-crossmember bolts and tighten. Torque all crossmember bolts to specification. Align the driveshaft with the rear differential pinion flange using the alignment marks made during removal. Install the four driveshaft-to-differential bolts and torque to specification. Verify the driveshaft rotates freely and has proper clearance to surrounding components.
17. 17

    Reinstall exhaust and complete final connections
    Reconnect the exhaust system to the headers, aligning slip-fit connections and installing clamps. Reinstall all exhaust hangers to properly support the system. Reconnect oxygen sensors if disconnected. Verify exhaust has proper clearance to transmission, driveshaft, and frame components. Refill the transmission with the OEM-specified manual transmission fluid for the 2008 Viper TR6060, filling until fluid is level with the bottom of the fill hole (verify exact fluid specification and capacity against the factory service manual). Install both rear wheels and torque lug nuts to specification. Lower the vehicle to the ground. Reconnect the negative battery cable.

Reassembly

1. Reinstallation follows the reverse order of removal with specific attention to torque specifications
2. Always use new flywheel bolts (TTY type) and apply thread locking compound
3. Ensure clutch disc is properly oriented with damper springs facing the pressure plate
4. Use clutch alignment tool throughout installation to prevent input shaft or clutch disc damage
5. Torque all fasteners to specification in the proper sequence
6. Verify all electrical connections and hydraulic lines are properly secured before operation

Verification

• Before starting engine, verify transmission shifts through all gears with clutch pedal depressed (engine off)
• Check transmission fluid level at the fill plug - fluid should be level with the bottom of the fill hole
• Start engine and verify no abnormal noises from flywheel or clutch area
• With engine idling, verify clutch disengages smoothly and transmission can be shifted into gear without grinding
• Test drive vehicle and verify smooth clutch engagement and disengagement through all gears
• Check for fluid leaks at transmission, clutch hydraulic line, and rear differential after test drive
• Verify no exhaust leaks at header connections
• Listen for any vibration or unusual noises that could indicate improper flywheel installation or driveshaft misalignment

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