Rear Main Seal

Remove and replace the rear main crankshaft seal on a 2008 Dodge Viper 8.4L V10, requiring transmission and clutch removal for access.

Warnings

Tools required

Parts

• Rear main crankshaft seal × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Clutch disc (if contaminated with oil) × 1 — Use OEM specification
• Pressure plate (if clutch disc is replaced) × 1 — Use OEM specification
• Throw-out bearing × 1 — Use OEM specification
• Transmission mounting bolts (if thread-locking type) × 1 — Use OEM specification

Fluids

• Pennzoil Synchromesh 75W-90 — 4.2 qt
• 0W-40 full synthetic engine oil — 11 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Allow engine to cool completely if recently operated
4. Raise vehicle and support securely on jack stands at all four corners
5. Remove engine oil drain plug and drain engine oil completely into appropriate container
6. Reinstall drain plug after draining
7. Remove rear wheels for improved access to exhaust and suspension components
8. Install engine support bar across engine bay or attach hoist to engine lift points to support engine weight during transmission removal

Procedure

1. 1

   Remove exhaust system components
   Disconnect exhaust system starting from catalytic converter flanges. Remove hangers supporting mid-pipe and muffler sections. Lower exhaust system rearward and away from transmission bellhousing. Complete exhaust removal may be necessary depending on clearance requirements for transmission extraction.
2. 2

   Disconnect driveshaft
   Mark driveshaft-to-differential flange alignment with paint or punch marks for correct reinstallation phasing. Remove the 4 bolts securing rear driveshaft flange to differential companion flange. Support driveshaft and slide it rearward to disengage from transmission output shaft. Cap transmission output shaft opening with plastic bag to prevent fluid loss.
3. 3

   Disconnect shifter linkage and wiring
   From underneath vehicle, disconnect shift linkage from transmission. Remove shift linkage support bracket bolts. Disconnect reverse light switch electrical connector. Disconnect vehicle speed sensor connector if equipped. Tag all connections for reassembly reference.
4. 4

   Remove clutch slave cylinder
   Locate hydraulic clutch slave cylinder on transmission bellhousing. Remove the mounting bolts securing slave cylinder. Carefully move slave cylinder aside without disconnecting hydraulic line. Support with wire or bungee cord to avoid stress on hydraulic line. Do not depress clutch pedal with slave cylinder disconnected.
5. 5

   Support and remove transmission crossmember
   Position transmission jack under transmission with appropriate saddle to distribute load. Raise jack slightly to take weight off crossmember. Remove bolts securing transmission mount to crossmember. Remove crossmember-to-frame bolts and remove crossmember from vehicle.
6. 6

   Remove transmission-to-bellhousing bolts
   Locate and remove all bellhousing-to-engine block bolts. There are multiple bolts around the bellhousing perimeter, including some accessible only from above through the cabin area. Ensure engine support is secure before removing final bolts. Lower transmission slightly on jack and pull rearward to disengage input shaft from clutch disc and pilot bearing. Guide transmission out from under vehicle, ensuring input shaft clears clutch assembly without binding.
7. 7

   Remove pressure plate and clutch disc
   Insert flywheel holding tool into flywheel teeth or use appropriate method to prevent flywheel rotation. Gradually loosen the 6 pressure plate-to-flywheel bolts in a star pattern, loosening each bolt 2-3 turns at a time to prevent warping pressure plate. Remove all bolts and carefully remove pressure plate and clutch disc assembly. Inspect clutch disc for oil contamination; replace if any oil is present on friction material.
8. 8

   Remove flywheel
   With flywheel holding tool still engaged, remove the flywheel-to-crankshaft bolts. Mark flywheel position relative to crankshaft with paint mark before removal to maintain balance relationship. Remove flywheel carefully, noting any dowel pins or alignment features. Set flywheel aside on clean surface with friction surface protected. Note: Mark flywheel-to-crankshaft position before removal to preserve balance orientation; avoid unnecessary crankshaft rotation with the flywheel off to keep clutch/flywheel timing marks aligned for reassembly.
9. 9

   Remove rear main seal
   Inspect rear main seal housing for seal design (one-piece or two-piece). For one-piece rear main seal, carefully pry seal out using plastic pry tools, working around perimeter. Take care not to score crankshaft sealing surface or damage seal bore in block/housing. Clean all old seal material and any RTV residue from seal bore and crankshaft surface using appropriate solvent and clean lint-free rags. Inspect crankshaft seal surface for grooves, scratches, or wear that would prevent proper seal function.
10. 10

    Install new rear main seal
    Verify new seal matches old seal in dimensions and design. Lightly lubricate seal lip with clean engine oil. Apply light coat of engine oil to crankshaft sealing surface. Using appropriate rear main seal installation tool or large socket/driver that contacts only outer seal edge, carefully drive new seal into bore squarely. Seal should be installed flush with housing face or to depth specified by alignment features on seal or bore. Verify seal is seated evenly around entire circumference before proceeding.
11. 11

    Reinstall flywheel
    Clean flywheel mounting surface on crankshaft and back face of flywheel thoroughly. Align flywheel to crankshaft using alignment marks made during removal, ensuring any dowel pins are properly engaged. Apply thread-locking compound to flywheel bolt threads if specified. Install flywheel bolts and use flywheel holding tool to prevent rotation. Torque flywheel bolts to specification in a star pattern.
12. 12

    Install clutch assembly
    Clean flywheel friction surface with brake cleaner; do not use oil or leave fingerprints. Place new or cleaned clutch disc against flywheel with proper orientation (marked side typically faces pressure plate, or longer hub faces transmission). Insert clutch alignment tool through clutch disc and into pilot bearing to maintain alignment. Position pressure plate over clutch disc and alignment tool. Start all 6 pressure plate bolts by hand. Using flywheel holding tool, gradually tighten pressure plate bolts in star pattern, tightening each bolt progressively to prevent disc distortion. Torque to specification. Remove alignment tool only after transmission input shaft is ready for installation.
13. 13

    Prepare transmission for installation
    Inspect transmission input shaft for damage, replace input shaft seal if showing any wear. Install new throw-out bearing onto clutch fork or slave cylinder actuator. Lubricate input shaft splines lightly with high-temperature clutch grease. Verify clutch alignment tool is still in place in pilot bearing before lifting transmission.
14. 14

    Install transmission
    Position transmission on transmission jack and raise into position. Carefully align transmission input shaft with clutch disc splines and pilot bearing. Input shaft must slide through clutch disc and into pilot bearing smoothly without binding. If binding occurs, slightly rotate transmission output shaft while applying light forward pressure to help splines engage. Once input shaft is fully seated, slide transmission forward until bellhousing seats flush against engine block. Install all bellhousing-to-engine bolts and tighten progressively. Torque to specification.
15. 15

    Reinstall remaining components
    Reinstall transmission crossmember and torque mounting bolts to specification. Remove transmission jack. Reinstall clutch slave cylinder and torque mounting bolts. Reconnect all electrical connectors (reverse light switch, speed sensor). Reinstall shift linkage and support bracket, ensuring smooth shifter operation. Reinstall driveshaft, aligning marks made during removal, and torque flange bolts to specification. Reinstall exhaust system components and secure all hangers. Reinstall rear wheels and torque lug nuts to specification.
16. 16

    Refill fluids and final checks
    Lower vehicle from jack stands. Refill engine with 11.0 quarts of 0W-40 full synthetic engine oil. Refill transmission with 4.2 quarts of Pennzoil Synchromesh 75W-90 through fill plug. Reconnect battery negative cable. Start engine and check for oil leaks around rear main seal area. Allow engine to idle and verify proper clutch pedal feel and operation. Check for abnormal noises from transmission or clutch.

Reassembly

1. Torque all fasteners to manufacturer specifications in proper sequence
2. Ensure all electrical connectors are fully seated and locked
3. Verify driveshaft phasing alignment marks are matched during reinstallation
4. Bleed clutch hydraulic system if any air entered during slave cylinder removal
5. Check all fluid levels after completion and road test

Verification

• Start engine and verify no oil leaks from rear main seal area with engine idling for 5 minutes
• Verify proper clutch engagement and disengagement with smooth operation through all gears
• Check engine oil level is correct after running engine
• Test drive vehicle and verify smooth shifting, no clutch slippage, and no unusual noises from drivetrain
• Re-inspect rear main seal area for leaks after test drive and overnight observation

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