Transmission R&R - Manual

Complete removal and reinstallation of the Tremec TR-6060 6-speed manual transmission from a 2008 Dodge Viper, including driveline disconnection, crossmember removal, and bellhousing separation.

Warnings

Tools required

Parts

• Transmission gasket/sealant (if required) × 1 — Use OEM specification
• Clutch kit (if replacement needed) × 1 — Use OEM specification
• Rear main seal (inspection/replacement) × 1 — Use OEM specification
• Transmission mount hardware (if worn) × 1 — Use OEM specification

Fluids

• transmission_manual — 4.2 qt

Preparation

1. Ensure the vehicle is on a level, stable surface with adequate clearance for undercar access.
2. Disconnect the negative battery cable and isolate it from the battery terminal.
3. Raise the vehicle using a floor jack and support it securely on jack stands at all four corners. The vehicle must be level and stable.
4. Remove the rear wheels to provide access and additional working clearance if needed.
5. Allow the exhaust system to cool completely if the vehicle was recently operated.
6. Place a drain pan under the transmission and drain the gear oil by removing the drain plug at the bottom of the transmission case.
7. Reinstall the drain plug finger-tight to prevent spillage during removal.

Procedure

1. 1

   Remove shifter assembly and boot
   From inside the vehicle cabin, remove the shift knob by turning counterclockwise. Remove the shift boot by releasing the retaining clips or fasteners securing it to the console. The TR-6060 shifter assembly mounts through the floor tunnel to the transmission. Remove the fasteners securing the shifter/tower to the transmission (verify exact bolt count against the 2008 Viper factory service manual). Lift the entire shifter assembly out of the transmission, taking care not to damage the rubber boot or seals.
2. 2

   Disconnect driveshaft
   Mark the relationship between the driveshaft and the differential flange using a paint pen to ensure correct phasing on reassembly. Remove the 4 bolts securing the rear U-joint or CV flange to the rear differential flange. Support the driveshaft and carefully slide it rearward to disengage the front splines from the transmission output shaft. Some transmission fluid may drain from the tailshaft housing. Lower the driveshaft and remove it from under the vehicle.
3. 3

   Disconnect exhaust system
   The transmission removal requires clearance from the exhaust system. Disconnect the exhaust at the mid-pipe connection or header collector flanges. Remove the hangers supporting the exhaust near the transmission crossmember area. Lower or move the exhaust system to provide adequate clearance for transmission removal. You may need to completely remove sections depending on workspace constraints.
4. 4

   Disconnect clutch hydraulics and speed sensor
   Locate the hydraulic clutch line connected to the clutch slave cylinder (mounted to the bellhousing or internally within the bellhousing). Disconnect the hydraulic line at the quick-disconnect fitting or remove the hardline mounting bolts. Cap or plug the line to prevent fluid loss. Disconnect any transmission-mounted electrical connectors present (verify whether a discrete vehicle speed sensor is used on this transmission against the 2008 Viper factory service manual). Disconnect any other electrical connectors including the reverse light switch and backup lamp switch.
5. 5

   Support transmission with transmission jack
   Position the transmission jack under the transmission pan, centering it to balance the weight. Secure the transmission to the jack using safety chains or straps. Raise the jack slightly to take the weight off the transmission mount, but do not lift the transmission yet. Ensure the jack is stable and the transmission is securely attached before proceeding.
6. 6

   Remove transmission crossmember
   With the transmission weight supported by the jack, locate the transmission crossmember that spans the frame rails and supports the transmission mount. Remove the bolts securing the transmission mount to the crossmember (typically 2-4 bolts). Then remove the bolts securing the crossmember to the frame rails on each side (typically 2-4 bolts per side). Carefully lower and remove the crossmember from the vehicle.
7. 7

   Remove bellhousing-to-engine bolts
   Locate all bellhousing bolts securing the transmission to the engine block. The TR-6060 bellhousing is secured to the engine block by several perimeter bolts of varying lengths (verify exact bolt count and locations against the 2008 Viper factory service manual). Note the location and length of each bolt as they are not interchangeable. Remove all bellhousing bolts using a combination of extensions and universal joints to access the upper bolts. Some bolts may be accessed more easily from above through the engine bay. Do not rely on the estimated torque value; confirm the bellhousing bolt torque spec against the 2008 Viper factory service manual before reassembly.
8. 8

   Remove starter motor
   The starter motor may interfere with transmission removal or access to bellhousing bolts. Disconnect the starter electrical connections (main battery cable and trigger wire). Remove the bolts securing the starter to the bellhousing (typically 2-3 bolts). Remove the starter motor from the vehicle.
9. 9

   Separate transmission from engine
   Double-check that all bellhousing bolts, electrical connections, hydraulic lines, and driveline components are disconnected. Ensure the transmission jack is secure and stable. Carefully slide the transmission rearward, keeping it aligned with the engine crankshaft centerline. The transmission input shaft must slide straight out of the clutch disc and pilot bearing without binding. If resistance is felt, stop and verify all fasteners are removed and the transmission is properly aligned. Once the input shaft clears the clutch assembly, carefully lower the transmission jack and roll it out from under the vehicle.
10. 10

    Inspect clutch assembly and flywheel
    With the transmission removed, inspect the clutch disc, pressure plate, and flywheel for wear, hot spots, or damage. Check the flywheel surface for scoring or heat cracks. Inspect the pilot bearing in the crankshaft for wear or roughness. Check the clutch fork and release bearing for wear. This is the ideal time to replace the clutch assembly if any components show significant wear. Inspect the rear main seal for leaks and replace if necessary.

Reassembly

1. Apply a small amount of high-temperature grease to the input shaft splines and pilot bearing.
2. If the clutch was replaced, use a clutch alignment tool to center the clutch disc on the flywheel before installing the transmission.
3. Carefully align the transmission input shaft with the clutch disc splines and pilot bearing. Slide the transmission forward slowly, rotating the output shaft slightly if needed to engage the splines.
4. Install all bellhousing bolts finger-tight first, then torque in a star pattern to ensure even seating. Upper bolts are typically torqued first, then lower bolts.
5. Reinstall the starter motor and electrical connections.
6. Reinstall the transmission crossmember and mount, ensuring proper alignment before torquing fasteners.
7. Reconnect the driveshaft to the differential flange, aligning the marks made during disassembly. Torque the U-joint or flange bolts evenly in a cross pattern.
8. Reconnect all electrical connectors including speed sensor, reverse light switch, and any other sensors.
9. Reconnect the clutch hydraulic line and bleed the clutch system if the line was disconnected.
10. Reinstall the shifter assembly, ensuring the shift tower seals properly to the transmission housing.
11. Reinstall the exhaust system and all hangers, ensuring proper clearance from the transmission and driveline.
12. Refill the transmission with 4.2 quarts of Pennzoil Synchromesh 75W-90 gear oil through the fill plug until oil reaches the bottom of the fill hole.
13. Reinstall rear wheels if removed and lower the vehicle to the ground.
14. Reconnect the negative battery cable.

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 and smooth operation.
• Check for fluid leaks around the transmission case, shifter tower, drain plug, and fill plug.
• Test drive the vehicle through all gears under light load, verifying smooth shifting and proper clutch engagement.
• Check driveline for vibration. Any vibration may indicate improper driveshaft phasing or unbalanced components.
• Recheck transmission fluid level after test drive and top off if necessary.
• Verify proper operation of the reverse lights and speedometer.

Related trouble codes on this vehicle

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