Transmission Output Shaft Bearing

Remove and replace the transmission output shaft bearing on a 2008 Dodge Viper with TR6060 6-speed manual transmission, requiring transmission removal and partial disassembly.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification or Timken/SKF equivalent
• Transmission rear seal × 1 — Use OEM specification
• Transmission gasket set × 1 — Use OEM specification
• Driveshaft bolts (if reuse not recommended) × 4 — Use OEM specification
• Transmission mount hardware (if worn) × 1 — Use OEM specification

Fluids

• Pennzoil Synchromesh 75W-90 — 4.2 qt

Preparation

1. Park vehicle on a level surface and engage parking brake.
2. Disconnect negative battery cable.
3. Raise vehicle on lift or support securely on jack stands at all four corners, ensuring adequate working clearance underneath.
4. Remove exhaust system from catalytic converters rearward to provide transmission clearance.
5. Allow transmission to cool if vehicle was recently operated.
6. Place drain pan under transmission drain plug location.
7. Have all replacement parts, fluids, and tools readily accessible before beginning disassembly.

Procedure

1. 1

   Drain transmission fluid
   Locate the transmission drain and fill plugs (verify the TR6060 in this application has a dedicated drain plug; some variants drain via the fill port). Remove the drain plug and drain transmission fluid completely into a suitable container. Reinstall drain plug hand-tight for now (will be torqued during final reassembly).
2. 2

   Remove driveshaft
   Mark the driveshaft-to-differential flange alignment for installation reference. Remove the 4 bolts securing the driveshaft to the rear differential flange. Support the driveshaft and slide it rearward to disengage the slip yoke from the transmission output shaft. Cap or plug the transmission extension housing to prevent fluid seepage and contamination.
3. 3

   Disconnect shift linkage and electrical connections
   Remove the shifter assembly from the top of the transmission (the Viper TR6060 uses a direct-mount shifter, not remote linkage). Remove the shifter retaining bolts/fasteners and set the shifter aside. Disconnect all transmission electrical connectors present, including the reverse light/backup lamp switch and any output/vehicle speed sensor connector (verify connector complement for this TR6060 application). Disconnect the clutch hydraulic line at the slave cylinder mounted to the transmission bellhousing. Cap the line to prevent fluid loss and contamination.
4. 4

   Support engine and remove crossmember
   Install an engine support fixture or position a jack with a block of wood under the oil pan to support engine weight. Remove the transmission mount-to-crossmember fasteners. Remove the crossmember-to-frame fasteners and remove the crossmember from the vehicle.
5. 5

   Remove bellhousing and transmission mounting bolts
   Remove the starter motor by disconnecting electrical connections and removing the mounting bolts. Remove all bellhousing-to-engine block bolts. Remove all bellhousing-to-engine block bolts (verify exact count and lengths against 2008 Viper TR6060 service documentation). Note the location of each bolt length for reassembly. Note the location of each bolt length for reassembly.
6. 6

   Remove transmission from vehicle
   Position a transmission jack under the transmission and secure it with safety chains or straps. Support the transmission weight on the jack. Carefully slide the transmission rearward, keeping it level, until the input shaft clears the clutch assembly and pilot bearing. Lower the transmission gradually and remove it from under the vehicle. Place the transmission on a sturdy workbench or transmission stand.
7. 7

   Remove extension housing
   With the transmission secured on a workbench, remove the bolts securing the extension housing (tailhousing) to the rear of the transmission case. Remove the extension housing bolts (verify exact count against TR6060 service documentation). Carefully pry the extension housing away from the case using a soft-faced mallet or plastic pry tool. Remove the housing and gasket. Verify the exact location of the failed output shaft bearing against TR6060 service documentation; the extension housing typically carries the output shaft rear seal and bushing, while the main output shaft bearing may reside in the case/rear bearing retainer.
8. 8

   Inspect output shaft and bearing condition
   Inspect the output shaft for wear, scoring, or heat discoloration in the bearing contact area. Measure the output shaft diameter at the bearing journal with a micrometer if available to verify it is within specification. Inspect the old bearing for signs of the failure mode (pitting, cage damage, excessive play, or noise). This information helps confirm the bearing was the root cause and no additional output shaft damage exists.
9. 9

   Remove output shaft bearing from extension housing
   The bearing is pressed into the extension housing. Use a bearing puller, slide hammer with internal puller attachment, or hydraulic press to remove the bearing from the housing bore. If using a puller, grip behind the bearing inner race and pull straight out. If using a press, support the housing securely and press the bearing out from the front side. Avoid damaging the housing bore during removal.
10. 10

    Clean and inspect extension housing bore
    Thoroughly clean the extension housing bearing bore with solvent and shop towels. Inspect the bore for scoring, cracks, or damage. The bore must be smooth and free of debris for proper bearing installation. Check the bore for roundness if measurement tools are available.
11. 11

    Install new output shaft bearing
    Place the new bearing in the freezer for 30-60 minutes before installation to aid fitment (optional but recommended). Position the new bearing squarely at the extension housing bore entrance, ensuring correct orientation (bearing numbers/markings face outward). Using a bearing driver or press, drive or press the bearing straight into the housing bore until it is fully seated against the internal shoulder. The bearing must be driven on the outer race only, never on the inner race or balls/rollers. Verify the bearing is fully seated and spins freely.
12. 12

    Install new rear seal in extension housing
    Install a new rear seal into the extension housing. Position the seal with the lip facing inward toward the transmission. Use a seal driver or large socket to drive the seal squarely into the housing bore until flush with the housing face. Apply a light coat of clean transmission fluid to the seal lip.
13. 13

    Reinstall extension housing to transmission
    Clean the extension housing and transmission case mating surfaces thoroughly. Seal the extension housing using the factory-specified method for the TR6060 (verify whether a gasket or specific anaerobic/RTV sealant is required before assembly). Carefully slide the extension housing onto the output shaft and align it with the transmission case. Install all extension housing bolts and tighten in a criss-cross pattern to draw the housing evenly into place. Tighten the extension housing bolts to the factory-specified torque for the TR6060 (verify against service documentation before final tightening).
14. 14

    Reinstall transmission into vehicle
    Apply a thin coat of high-temperature grease to the input shaft splines. Position the transmission on the transmission jack and raise it into position under the vehicle. Align the input shaft with the clutch disc splines and pilot bearing. Carefully slide the transmission forward, rotating the output shaft slightly if needed to engage the input shaft splines. Continue pushing the transmission forward until the bellhousing seats flush against the engine block. Do not use bellhousing bolts to draw the transmission into place; it must slide in freely.
15. 15

    Install bellhousing bolts and reinstall starter
    Install all bellhousing-to-engine block bolts, ensuring each bolt is in its correct location based on your disassembly notes. Tighten the bolts in a star pattern to the factory-specified torque, drawing the bellhousing evenly to the block (verify torque spec against 2008 Viper service documentation). Reinstall the starter motor and connect its electrical connections.
16. 16

    Reinstall crossmember and transmission mount
    Position the crossmember and install the crossmember-to-frame fasteners. Install the transmission mount-to-crossmember fasteners. Remove the engine support fixture or jack. Verify all mount fasteners are secure.
17. 17

    Reconnect shift linkage, hydraulic line, and electrical connections
    Reconnect the clutch hydraulic line to the slave cylinder. Reconnect all electrical connectors including reverse light switch and vehicle speed sensor. Reconnect the shift linkage to the transmission, ensuring all clips and fasteners are properly secured. Verify shift linkage operates smoothly through all gears.
18. 18

    Reinstall driveshaft
    Remove the cap or plug from the transmission output shaft. Lubricate the slip yoke with a light coat of transmission fluid. Slide the driveshaft forward, engaging the slip yoke with the output shaft splines. Align the driveshaft flange with the differential flange using your alignment marks. Install the driveshaft bolts (verify exact count) and tighten to the factory-specified torque for the 2008 Viper driveshaft-to-differential flange.
19. 19

    Reinstall exhaust system
    Reinstall the exhaust system from the catalytic converters rearward. Ensure all exhaust hangers are properly seated and all clamps or fasteners are secure. Verify adequate clearance between exhaust components and driveshaft, transmission, and chassis components.
20. 20

    Refill transmission with fluid
    Remove the transmission fill plug located on the side of the transmission case. Using a fluid pump, refill the transmission with the factory-specified quantity of the correct manual transmission fluid (verify exact fluid type and capacity against 2008 Viper/TR6060 service documentation). Fill until fluid reaches the bottom edge of the fill hole (fill-to-drip level), then verify total added quantity matches factory-specified capacity. Reinstall the fill plug and tighten securely. Tighten the drain and fill plugs to the factory-specified torque for the TR6060 (verify against service documentation).

Reassembly

1. Torque all fasteners to manufacturer specifications when available.
2. Verify all electrical connections are properly seated and secured.
3. Ensure shift linkage operates smoothly through all gears before lowering vehicle.
4. Double-check that all bellhousing bolts are installed and tightened.
5. Verify driveshaft alignment marks are properly indexed.

Verification

• Reconnect negative battery cable.
• Start the engine and verify no fluid leaks from transmission, extension housing, or hydraulic clutch line.
• With engine running and clutch pedal depressed, verify smooth engagement into all gears.
• Test drive the vehicle through all gears, verifying smooth shifting and no abnormal noises from the transmission or output shaft bearing area.
• Check transmission fluid level after test drive and top off if necessary.
• Verify no driveline vibration or unusual noises during acceleration and deceleration.
• Re-inspect all fasteners and connections after test drive to confirm nothing has loosened.

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