2003 Dodge RAM Standard Owners Manual

SLP

UD

OD

P–PARK

R–REVERSE N-NEUTRAL

D–OVERDRIVE

FIRST

SECOND

SECOND PRIME

THIRD FOURTH

FIFTH LIMP-IN 2–FIRST SECOND LIMP-IN 1–LOW

ON

ON ON ON

ON ON ON ON ON

ON ON ON ON

2C

4C

ON

ON

ON

ON

ON

ON ON

L/R

ON ON ON

ON*

ON*

ON

*L/R clutch is on only with the output shaft speed below 150 rpm.

DR

OVERRUNNING

ON

ON

ON

OVERRUNNING

ON

ON

ON

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued) DIAGNOSIS AND TESTING - HYDRAULIC PRESSURE TEST

AUTOMATIC TRANSMISSION - 45RFE/545RFE

21 - 493

An accurate tachometer and pressure test gauges are required. Test Gauge C-3293-SP has a 300 psi range and is used at all locations where pressures exceed 100 psi.

Pressure Test Port Locations

Only two pressure ports are supplied on the trans- mission case. The torque converter clutch apply and release ports are located on the right side of the transmission case (Fig. 2).

Fig.3PressureTapLocations

Fig.2TorqueConverterPressureLocations

1 - TCC RELEASE 2 - TO COOLER 3 - TCC APPLY 4 - FROM COOLER 5 - LINE PRESSURE SENSOR

To determine the line pressure, there are two avail- able methods. The DRBt scan tool can be used to read line pressure from the line pressure sensor. The second method is to install Line Pressure Adapter 8259 (Fig. 4) into the transmission case and then install the pressure gauge and the original sensor into the adapter. This will allow a comparison of the DRBt readings and the gauge reading to determine the accuracy of the line pressure sensor. The DRBt line pressure reading should match the gauge read- ing within ±10 psi.

In order to access any other pressure tap locations, the transmission oil pan must be removed, the pres- sure port plugs removed and Valve Body Pressure Tap Adapter 8258-A (Fig. 5) installed. The extensions supplied with Adapter 8258-A will allow the installa- tion of pressure gauges to the valve body. Refer to (Fig. 3) for correct pressure tap location identifica- tion.

Fig.4LinePressureAdapter8259

1 - LINE PRESSURE SENSOR PORT 2 - LINE PRESSURE SENSOR 3 - TOOL 8259
4 - PRESSURE TAP

TEST PROCEDURE

All pressure readings should be taken with the transmission fluid level full, transmission oil at the normal operating temperature, and the engine at 1500 rpm. Check the transmission for proper opera- tion in each gear position that is in question or if a specific element is in question, check the pressure readings in at least two gear positions that employ that element. Refer to the Hydraulic Schematics at the rear of this section to determine the correct pres- sures for each element in a given gear position.

21 - 494
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

DR

DOWNSHIFT PRESSURES

5-4

5-3

5-2

4-3

4-2
prime

3-2

3-2
prime

135

135

135

135

135

135

135

120

120

120

120

120

120

120

prime -1

135

120

2-1

3-1

135

135

120

120

ENG- INE

5.7L

3.7L/ 4.7L

IN-GEAR PRESSURES

ENGINE

160

135

5.7L

3.7L/ 4.7L

135

120

prime

135

120

135

120

135

120

135

120

NEUT- RAL

REV- ERSE

120

120

250

220

DIAGNOSIS AND TESTING - AIR CHECKING TRANSMISSION CLUTCH OPERATION

Air-pressure testing can be used to check transmis- sion clutch operation. The test can be conducted with the transmission either in the vehicle or on the work bench, as a final check.

Air-pressure testing requires that the oil pan and valve body be removed from the transmission. The clutch apply passages are shown (Fig. 6).

Fig.6AirPressureTestPassages

1 - LOW REVERSE CLUTCH 2 - 4TH CLUTCH 3 - 2ND CLUTCH 4 - OVERDRIVE CLUTCH 5 - UNDERDRIVE CLUTCH 6 - REVERSE CLUTCH

Fig.5ValveBodyPressureTapAdapter8258-A

1 - 45RFE TRANSMISSION 2 - TOOL 8258-A

NOTE: The 45RFE/545RFE utilizes closed loop con- trol of pump line pressure. The pressure readings may therefore vary greatly but should always follow line pressure.

Some common pressures that can be measured to evaluate pump and clutch performance are the upshift/downshift pressures, garage shift pressures, and TCC pressure. The upshift/downshift pressure for all shifts are shown in UPSHIFT PRESSURES and DOWNSHIFT PRESSURES. In-gear maximum pressure for each gear position is shown in IN-GEAR PRESSURES. The garage shift pressure when per- forming a N-R shift is 220 psi for 3.7L/4.7L equipped vehicles and 250 psi for 5.7L equipped vehicles. The garage shift pressure for the R-N shift is 120 psi. The garage shift pressure for the N-1 shift is 135 psi for 3.7L/4.7L equipped vehicles and 165 psi for 5.7L equipped vehicles. Torque converter lock-up pressure is 120 psi for 3.7L/4.7L equipped vehicles and 125 psi for 5.7L equipped vehicles.

UPSHIFT PRESSURES

ENGINE

5.7L

3.7L/ 4.7L

1-2

150

120

2-3

125

120

2prime-3

125

120

3-4

135

120

2prime-4

135

120

2-5

135

120

3-5

135

120

4-5

135

130

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

21 - 495

NOTE: The air supply which is used must be free of moisture and dirt. Use a pressure of 30 psi to test clutch operation.

Apply air pressure at each port. If the clutch is functioning, a soft thump will be heard as the clutch is applied. The clutch application can also be felt by touching the appropriate element while applying air pressure. As the air pressure is released, the clutch should also release.

DIAGNOSIS AND TESTING - CONVERTER HOUSING FLUID LEAK

When diagnosing converter housing fluid leaks,

two items must be established before repair.

(1) Verify that a leak condition actually exists. (2) Determined the true source of the leak. Some suspected converter housing fluid leaks may not be leaks at all. They may only be the result of residual fluid in the converter housing, or excess fluid spilled dur- ing factory fill or fill after repair. Converter housing leaks have several potential sources. Through careful observation, a leak source can be identified before remov- ing the transmission for repair. Torque converter seal leaks tend to move along the drive hub and onto the rear of the converter. Pump cover seal tend to run down the cover and the inside surface of the bellhousing.

Some leaks, or suspected leaks, may be particu- If necessary, a Mopart

larly difficult approved dye may be used to locate a leak.

to locate.

TORQUE CONVERTER LEAK POINTS

Possible sources of converter leaks are: (1) Leaks at the weld joint around the outside

diameter weld (Fig. 7).

(2) Leaks at the converter hub weld (Fig. 7).

Fig.7TorqueConverterAssembly

1 - TURBINE ASSEMBLY 2 - STATOR 3 - CONVERTER HUB 4 - O-RING 5 - IMPELLER ASSEMBLY 6 - CONVERTER CLUTCH PISTON 7 - TURBINE HUB

(4) Mark propeller

shaft and axle companion

flanges for assembly alignment.

(5) Remove the rear propeller shaft (6) Remove the front propeller shaft, if necessary. (7) Remove the engine to transmission collar (Fig. 8).

STANDARD PROCEDURE - ALUMINUM THREAD REPAIR

Damaged or worn threads in the aluminum trans- mission case and valve body can be repaired by the use of Heli-Coils™, or equivalent. This repair con- sists of drilling out the worn-out damaged threads. Then tap the hole with a special Heli-Coil™ tap, or equivalent, and installing a Heli-Coil™ insert, or equivalent, into the hole. This brings the hole back to its original thread size.

Heli-Coil™, or equivalent,

tools and inserts are readily available from most automotive parts suppliers.

REMOVAL

(1) Disconnect the negative battery cable. (2) Raise and support the vehicle (3) Remove any necessary skid plates. (Refer to 13
- FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - REMOVAL)

Fig.8TransmissionCollar

1 - ENGINE 2 - ENGINE TO TRANSMISSION COLLAR 3 - TRANSMISSION

(8) Remove the exhaust support bracket from the

rear of the transmission.

21 - 496
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

DR

(9) Disconnect and lower or remove any necessary

exhaust components.

(10) Remove the starter motor. (11) Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.

(12) Disengage the output speed sensor connector

from the output speed sensor (Fig. 9).

(13) Disengage the input speed sensor connector

from the input speed sensor (Fig. 10).

(14) Disengage

transmission solenoid/TRS assembly connector from the transmission solenoid/ TRS assembly (Fig. 11).

the

(15) Disengage the line pressure sensor connector

from the line pressure sensor (Fig. 12).

Fig.11DisconnectTransmissionSolenoid/TRS

Assembly

1 - TRANSMISSION 2 - TRANSMISSION SOLENOID/TRS ASSEMBLY

Fig.9DisconnectOutputSpeedSensor

1 - TRANSMISSION 2 - OUTPUT SPEED SENSOR

Fig.12DisconnectLinePressureSensor

1 - TRANSMISSION 2 - LINE PRESSURE SENSOR

Fig.10DisconnectInputSpeedSensor

1 - TRANSMISSION 2 - INPUT SPEED SENSOR

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

21 - 497

(16) Disconnect gearshift cable from transmission

manual valve lever (Fig. 13).

Fig.14RemoveTransmission

1 - ENGINE 2 - TRANSMISSION

(4) Remove the manual shift lever from the trans-

mission.

(5) Remove the input, output, and line pressure

sensors from the transmission case (Fig. 15).

Fig.13GearshiftCableatTransmission-RFE

1 - GEARSHIFT CABLE 2 - RFE TRANSMISSION 3 - MANUAL LEVER

(17) Disconnect the transmission vent hose from

(18) Support rear of engine with safety stand or

the transmission.

jack.

(19) Raise transmission slightly with service jack

to relieve load on crossmember and supports.

(20) Remove bolts securing rear support and cush-

ion to transmission and crossmember.

(21) Remove transfer case, if necessary. (22) Disconnect transmission fluid cooler lines at

transmission fittings and clips.

(23) Remove all remaining converter housing bolts. (24) Carefully work transmission and torque con-

verter assembly rearward off engine block dowels.

(25) Hold torque converter in place during trans-

mission removal.

(26) Lower transmission and remove (Fig. 14)

assembly from under the vehicle.

(27) To remove torque converter, carefully slide

torque converter out of the transmission.

DISASSEMBLY

(1) Drain fluid from transmission. (2) Clean exterior of transmission with suitable

solvent or pressure washer.

(3) Remove the torque converter from the trans-

mission.

Fig.15RemoveInput,Output,andLinePressure

Sensors

1 - OUTPUT SPEED SENSOR 2 - LINE PRESSURE SENSOR 3 - INPUT SPEED SENSOR

21 - 498
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

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DR

(6) Inspect the ends of the sensors for debris, which may indicate the nature of the transmission failure.

(7) Install Support Stand 8257 onto the transmis-

sion case (Fig. 16).

clutch housing hub. This value should not be included in the end-play measured value and there- fore must be recorded and subtracted from the dial indicator reading.

(9) Remove the bolts holding the transmission extension/adapter housing to the transmission case. (10) Remove the extension/adapter housing from

the transmission case.

(11) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the output shaft end- play (Fig. 18).

Fig.16InstallSupportStand-Tool8257

1 - TOOL 8257

(8) Using Adapter 8266-1 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the input shaft end-play (Fig. 17).

Fig.18MeasureOutputShaftEndPlay

1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339

(12) Remove the bolts holding the transmission oil

pan to the transmission case.

(13) Remove the transmission oil pan from the

transmission case.

(14) Remove the primary oil

filter and the oil

cooler return filter (Fig. 19).

(15) Remove the cooler return filter bypass valve. (16) Remove the bolts holding the valve body to

the transmission case (Fig. 20).

(17) Remove the valve body from the transmission

case.

(18) Remove the outer snap-ring securing the transmission front cover into the transmission case (Fig. 21).

(19) Remove the inner snap-ring securing the

transmission front cover to the oil pump (Fig. 21).

(20) Reaching through a case opening in the valve body area with a long blunted tool, remove the trans- mission front cover from the transmission case.

(21) Remove the bolts holding the oil pump into

the transmission case (Fig. 22).

Fig.17MeasureInputShaftEndPlay

1 - TOOL 8266
2 - TOOL C-3339

NOTE: When measuring the input shaft end-play, two (stops( will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first (stop( felt when the input shaft is pulled out- ward is the movement of the input shaft in the input

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

21 - 499

Fig.19RemovePrimaryOilandCoolerFilters

1 - PRIMARY OIL FILTER 2 - COOLER RETURN FILTER 3 - COOLER RETURN FILTER BYPASS VALVE 4 - VALVE BODY

Fig.21RemoveTransmissionFrontCover

1 - INNER SNAP-RING 2 - TRANSMISSION COVER 3 - OUTER SNAP-RING

Fig.20RemoveValveBodyAssembly

1 - VALVE BODY TO CASE BOLT (6)

(22) Remove the oil pump. Hold inward on the to prevent pulling the input clutch

input shaft assembly with the oil pump (Fig. 22).

NOTE: If the input shaft is not held during oil pump removal, the input clutch assembly will attempt to move forward with the oil pump and the numbers 2, 3, or 4 bearings inside the input clutch assembly may become dislodged.

Fig.22RemoveOilPump

1 - OIL PUMP TO CASE BOLT (6) 2 - OIL PUMP

21 - 500
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

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DR

(23) Remove the number 1 bearing from the input

clutch assembly (Fig. 23).

(24) Remove the input clutch assembly from the

transmission case (Fig. 23).

(25) Remove the number 5 bearing and selective thrust plate from the input clutch assembly (Fig. 23), or the 4C clutch retainer/bulkhead.

Fig.24Remove4CClutchRetainer/Bulkhead

1 - SNAP-RING 2 - 4C CLUTCH RETAINER/BULKHEAD

Fig.23RemoveInputClutchAssembly

1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT) 3 - INPUT CLUTCH ASSEMBLY 4 - BEARING NUMBER 1

(26) Remove

the 4C clutch retainer/bulkhead tapered snap-ring from the transmission case (Fig. 24).

(27) Remove the 4C clutch retainer/bulkhead from

the transmission case (Fig. 24).

(28) Remove the front 2C clutch pack snap-ring

from the transmission case (Fig. 25).

(29) Remove the 2C clutch pack from the transmis-

sion case (Fig. 25).

(30) Remove the rear selective plate and number 6

bearing from the reaction annulus (Fig. 26).

(31) Remove the reaction annulus from the reac-

tion planetary carrier (Fig. 26).

(32) Remove the number 7 bearing (Fig. 26). (33) Remove the reaction sun gear (Fig. 26). (34) Remove the number 8 bearing from the reac-

tion planetary carrier (Fig. 26).

(35) Remove the reaction planetary carrier (Fig. 26). Note that this planetary gear set has three pin- ion gears.

(36) Remove the number 9 bearing from the

reverse planetary gear set (Fig. 26).

(37) Remove the snap-ring holding the park sprag

gear onto the output shaft (Fig. 27).

(38) Remove the park sprag gear from the output

shaft (Fig. 28).

Fig.25Remove2CClutchPack

1 - SNAP-RING 2 - PLATE 3 - DISC 4 - REACTION PLATE

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

21 - 501

Fig.26RemoveReactionAnnulusandCarrier

1 - BEARING NUMBER 8
2 - BEARING NUMBER 9
3 - REACTION PLANETARY CARRIER 4 - REACTION SUN GEAR

5 - BEARING NUMBER 7
6 - THRUST PLATE (SELECT) 7 - BEARING NUMBER 6
8 - REACTION ANNULUS

Fig.27RemoveParkSpragSnap-Ring

Fig.28RemoveParkSpragGear

1 - SNAP-RING

1 - PARK SPRAG GEAR

21 - 502
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

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(39) Remove the input/reverse planetary assembly

(46) Remove the park pawl pivot shaft, park pawl,

(Fig. 29).

and spring (Fig. 31).

(40) Remove the number 12 bearing from the

(47) Remove the manual selector shaft (Fig. 31).

input/reverse planetary assembly (Fig. 29).

Fig.29RemoveInput/ReversePlanetaryAssembly 1 - INPUT/REVERSE PLANETARY ASSEMBLY 2 - BEARING NUMBER 9
3 - BEARING NUMBER 12

(41) Remove the snap-ring holding the low/reverse clutch retainer into the transmission case (Fig. 30). (42) Remove the low/reverse clutch retainer from

the transmission case (Fig. 30).

Fig.31ManualShaft/ParkLockComponents

1 - GUIDE 2 - SNAP-RING 3 - SHAFT 4 - SPRING 5 - PARK PAWL 6 - MANUAL SHAFT/LEVER 7 - PARK ROD

(48) Remove the manual selector shaft seal. (49) Remove the dipstick tube seal.

CLEANING

The use of crocus cloth is permissible where neces- sary, providing it is used carefully. When used on shafts, or valves, use extreme care to avoid rounding off sharp edges. Sharp edges are vital as they pre- vent foreign matter from getting between the valve and valve bore.

Do not reuse oil seals, gaskets, seal rings, or O-rings during overhaul. Replace these parts as a matter of course. Also do not reuse snap rings or E-clips that are bent or distorted. Replace these parts as well.

Lubricate transmission parts with Mopart ATF +4, Automatic Transmission Fluid, during overhaul and assembly. Use petroleum jelly, Mopart Door Ease, or Ru-Glyde to prelubricate seals, O-rings, and thrust

Fig.30RemoveLow/ReverseClutchRetainer

1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY 2 - SNAP-RING

(43) Remove the park pawl rod and e-clip (Fig. 31). (44) Remove the park pawl rod guide snap-ring

(Fig. 31).

(45) Remove the park pawl rod guide (Fig. 31).

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

21 - 503

washers. Petroleum jelly can also be used to hold parts in place during reassembly.

Clean the case in a solvent tank. Flush the case bores and fluid passages thoroughly with solvent. Dry the case and all fluid passages with compressed air. Be sure all solvent is removed from the case and that all fluid passages are clear.

NOTE: Do not use shop towels or rags to dry the case (or any other transmission component) unless they are made from lint-free materials. Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem- bly. A sufficient quantity of lint can block fluid pas- sages and interfere with valve body operation.

INSPECTION

Inspect the case for cracks, porous spots, worn bores, or damaged threads. Damaged threads can be repaired with Helicoil thread inserts. However, the case will have to be replaced if it exhibits any type of damage or wear.

ASSEMBLY

Fig.32InstallSelectorShaft

1 - SEAL 2 - TOOL 8253

(1) Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.

(2) Install the cooler filter bypass valve. (3) Torque the bypass valve to specification. The valve uses a tapered pipe thread and excessive torque can damage the transmission case. Tighten the cooler filter bypass valve to 4.5 N·m (40 in.lbs.). (4) Install a new selector shaft seal using Seal

Installer 8253 (Fig. 32).

(5) Install the manual selector shaft and retaining screw. Tighten the manual selector shaft retaining screw to 28 N·m (250 in.lbs.).

(6) Install the park pawl, spring, and shaft (Fig.

(7) Install the park rod and e-clip (Fig. 33). (8) Install the park rod guide and snap-ring (Fig.

33).

33).

Fig.33ManualShaft/ParkLockComponents

1 - GUIDE 2 - SNAP-RING 3 - SHAFT 4 - SPRING 5 - PARK PAWL 6 - MANUAL SHAFT/LEVER 7 - PARK ROD

21 - 504
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

(9) Install a new dipstick tube seal using Seal

Installer 8254 (Fig. 34).

DR

Fig.34InstallDipstickTubeSealUsingTool8254
1 - TOOL 8254
2 - SEAL

1 - SNAP-RING 2 - PLATE 3 - DISC 4 - REACTION PLATE

Fig.35Install2CClutchPack

NOTE: Before final assembly of transmission cen- terline, the 2C/4C clutch components should be installed into position and measured as follows:

(10) Install the 2C reaction plate into the trans- mission case (Fig. 35). The reaction plate is direc- tional. The plate must be installed with the flat side toward the front of the transmission.

(11) Install the 2C clutch pack into the transmis-

sion case (Fig. 35).

(12) Install the flat 2C clutch snap-ring into the

transmission case (Fig. 35).

(13) Install

the 4C retainer/bulkhead into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area.

(14) Install

the 4C retainer/bulkhead tapered snap-ring into the transmission case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.

(15) Using a feeler gauge through the opening in the rear of the transmission case, measure the 2C clutch pack clearance between the 2C reaction plate and the transmission case at four different points. The average of these measurements is the 2C clutch pack clearance. The correct clutch clearance is 0.455- 1.335 mm (0.018-0.053 in.). The reaction plate is not selective. If the clutch pack clearance is not within specification, the reaction plate, all the friction discs, and steels must be replaced.

(16) Remove the 4C retainer/bulkhead and all of the 2C clutch components from the transmission case.

(17) Install the low/reverse clutch assembly (Fig. 36). Make sure that the oil feed hole points toward the valve body area and that the bleed orifice is aligned with the notch in the rear of the transmis- sion case.

(18) Install the snap-ring to hold the low/reverse clutch retainer into the transmission case (Fig. 36). The snap-ring is tapered and must be installed with the tapered side forward. Once installed, verify that the snap-ring is fully seated in the snap-ring groove.

Fig.36InstallLow/ReverseClutchRetainer

1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY 2 - SNAP-RING

(19) Air check the low/reverse clutch and verify

correct overrunning clutch operation.

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE

21 - 505

(20) Install the number 12 bearing over the output shaft and against the rear planetary gear set. The flat side of the bearing goes toward the planetary gearset and the raised tabs on the inner race should face the rear of the transmission.

(21) Install the reverse/input planetary assembly

through the low/reverse clutch assembly (Fig. 37).

Fig.39InstallParkSpragSnap-Ring

1 - SNAP-RING

Fig.37InstallInput/ReversePlanetaryAssembly

1 - INPUT/REVERSE PLANETARY ASSEMBLY 2 - BEARING NUMBER 9
3 - BEARING NUMBER 12

(24) Install the 2C reaction plate into the trans- mission case (Fig. 40). The reaction plate is direc- tional. The plate must be installed with the flat side toward the front of the transmission.

(25) Install the 2C clutch pack into the transmis-

sion case (Fig. 40).

(22) Install the park sprag onto the output shaft

(Fig. 38).

(23) Install the snap-ring to hold the park sprag

onto the output shaft (Fig. 39).

Fig.40Install2CClutchPack

1 - SNAP-RING 2 - PLATE 3 - DISC 4 - REACTION PLATE

Fig.38InstallParkSpragGear

1 - PARK SPRAG GEAR

(26) Install the number 8 bearing inside the reac- tion carrier with the outer race against the reaction planetary carrier.

21 - 506
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(27) Install the reaction planetary gear set and the number 9 bearing, with the inner race against the reaction planetary carrier, into the transmission case (Fig. 41).

(28) Install the flat 2C clutch snap-ring into the

transmission case (Fig. 40).

(29) Install the reaction sun gear into the reaction planetary gear set. Make sure the small shoulder is facing the front of the transmission (Fig. 41).

(30) Install the number 7 bearing onto the reaction sun gear with the inner race against the sun gear (Fig. 41).

(31) Install the output shaft selective thrust plate onto the reaction annulus with the oil grooves facing the annulus gear and the tabs and notches aligned as shown in (Fig. 42).

(32) Install the number 6 bearing against the output shaft selective thrust plate with the flat side against the thrust plate (Fig. 41) and the raised tabs on the inner race facing the front of the transmission.

(33) Install the reaction annulus into the reaction

planetary gear set (Fig. 41).

Fig.42ThrustPlateAlignment

1 - LOCATING LUG (3) 2 - THRUST PLATE

Fig.41InstallReactionAnnulusandCarrier

1 - BEARING NUMBER 8
2 - BEARING NUMBER 9
3 - REACTION PLANETARY CARRIER 4 - REACTION SUN GEAR

5 - BEARING NUMBER 7
6 - THRUST PLATE (SELECT) 7 - BEARING NUMBER 6
8 - REACTION ANNULUS

DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

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21 - 507

(34) Install

the 4C retainer/bulkhead into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area. Rotate the reaction annulus during the installation of the 4C retainer/bulkhead to ease installation.

(35) Install

the 4C retainer/bulkhead tapered snap-ring into the transmission case (Fig. 43) with the taper toward the front of the case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.

Fig.43Install4CClutchRetainer/Bulkhead

1 - SNAP-RING 2 - 4C CLUTCH RETAINER/BULKHEAD

(36) Air check the 2C and 4C clutch operation. (37) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the output shaft end- play (Fig. 44). The correct output shaft end-play is 0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary. Install the chosen output shaft selective thrust plate and re-measure end-play to verify selection.

(38) Apply a bead of RTV silicone and install the extension/adapter housing onto the transmission case.

(39) Install and torque the bolts to hold the exten- sion/adapter housing onto the transmission case. The correct torque is 54 N·m (40 ft.lbs.).

(40) Install the number 5 bearing and selective thrust plate onto the 4C retainer/bulkhead (Fig. 45). Be sure that the outer race of the bearing is against the thrust plate.

Fig.44MeasureOutputShaftEndPlay

1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339

(41) Install the input clutch assembly into the transmission case (Fig. 45). Make sure that the input clutch assembly is fully installed by performing a visual inspection through the input speed sensor hole. If the tone wheel teeth on the input clutch assembly are centered in the hole, the assembly is fully installed.

(42) Install the number 1 bearing with the outer race up in the pocket of the input clutch assembly (Fig. 45).

Fig.45InstallInputClutchAssembly

1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT) 3 - INPUT CLUTCH ASSEMBLY 4 - BEARING NUMBER 1

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(43) Install the oil pump into the transmission

case (Fig. 46).

(44) Install the bolts to hold the oil pump into the transmission case. Tighten the oil pump bolts to 28
N·m (250 in.lbs.).

Fig.46InstallOilPump

1 - OIL PUMP TO CASE BOLT (6) 2 - OIL PUMP

(45) Using Adapter 8266-1 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the input shaft end-play (Fig. 47). The correct end- play is 0.46-0.89 mm (0.018-0.035 in.). Adjust as nec- essary. Install the chosen thrust plate on the number 5 bearing and re-measure end-play to verify selec- tion.

NOTE: When measuring the input shaft end-play, two (stops( will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first (stop( felt when the input shaft is pulled out- ward is the movement of the input shaft in the input clutch housing hub. This value should not be included in the end-play measured value and there- fore must be recorded and subtracted from the dial indicator reading.

Fig.47MeasureInputShaftEndPlay

1 - TOOL 8266
2 - TOOL C-3339

Fig.48InstalltheTransmissionFrontCover

1 - INNER SNAP-RING 2 - TRANSMISSION COVER 3 - OUTER SNAP-RING

(46) Install the transmission front cover into the

transmission case (Fig. 48).

(47) Install the outer snap-ring to hold the trans- mission front cover into the transmission case (Fig. 48).

(48) Partially install the inner transmission front

cover snap-ring onto the oil pump (Fig. 48).

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(49) Using Installer 8255, install the inner trans- mission front cover snap-ring the remainder of the way onto the oil pump (Fig. 49).

install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result.

(52) Install the primary oil filter and the oil cooler return filter (Fig. 51). Tighten the screw to hold the pri- mary oil filter to the valve body to 4.5 N·m (40 in.lbs.). Using Oil Filter Wrench 8321, tighten the cooler return oil filter to the transmission case to 14 N·m (125 in.lbs.).

Fig.49SeatSnap-RingUsingTool8255

1 - TOOL 8255
2 - SNAP-RING

(50) Install the valve body (Fig. 50). Verify that the pin on the manual lever has properly engaged the TRS selector plate. Tighten the valve body to transmission case bolts to 12 N·m (105 in.lbs.).

Fig.51InstallPrimaryOilandCoolerFilters

1 - PRIMARY OIL FILTER 2 - COOLER RETURN FILTER 3 - COOLER RETURN FILTER BYPASS VALVE 4 - VALVE BODY

(53) Apply RTV silicone to the oil pan and install the transmission oil pan. Tighten the bolts to 12 N·m (105 in.lbs.).

(54) Install the input, output, and line pressure sen- sors (Fig. 52). Tighten the bolts to 12 N·m (105 in.lbs.).

Fig.50InstallValveBodyAssembly

1 - VALVE BODY TO CASE BOLT (6)

(51) Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool.

CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT

Fig.52InstallInput,Output,andLine

PressureSensors

1 - OUTPUT SPEED SENSOR 2 - LINE PRESSURE SENSOR 3 - INPUT SPEED SENSOR

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(55) Install the manual shift lever from the trans- mission. Torque the retaining cross-bolt to 16 N·m (140 in.lbs.).

INSTALLATION

(1) Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. Verify that the converter hub o-ring is properly installed and is free of any debris. The hub must be smooth to avoid damaging pump seal at installation.

(2) If

replacement

transmission is

being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement trans- mission.

(3) Lubricate oil pump seal lip with transmission

fluid.

(4) Align converter and oil pump. (5) Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.

(6) Check converter seating with steel scale and straightedge (Fig. 53). Surface of converter lugs should be at least 13mm (1/2 in.) to rear of straight- edge when converter is fully seated.

(7) Temporarily secure converter with C-clamp.

Fig.53CheckingTorqueConverterSeating-Typical 1 - SCALE 2 - STRAIGHTEDGE

(8) Position transmission on jack and secure it

with chains. (9) Check

condition

driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated

converter

of

in engine block and protrude far enough to hold transmission in alignment.

(10) Apply a light coating of Mopart High Temp Grease to the torque converter hub pocket in the rear pocket of the engine’s crankshaft.

(11) Raise transmission (Fig. 54) and align the torque converter with the drive plate and transmis- sion converter housing with the engine block.

Fig.54InstallTransmission

1 - ENGINE 2 - TRANSMISSION

(12) Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels.

(13) Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.

(14) Install two bolts to attach the transmission to

the engine.

(15) Install remaining torque converter housing to

engine bolts. Tighten to 68 N·m (50 ft.lbs.).

(16) Install

transfer case,

if equipped. Tighten

transfer case nuts to 35 N·m (26 ft.lbs.).

(17) Install rear support to transmission. Tighten

bolts to 47 N·m (35 ft.lbs.).

(18) Lower transmission onto crossmember and install bolts attaching transmission mount to cross- member. Tighten clevis bracket to crossmember bolts to 47 N·m (35 ft.lbs.). Tighten the clevis bracket to rear support bolt to 68 N·m (50 ft.lbs.). (19) Remove engine support fixture. (20) Connect gearshift cable to transmission.

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(21) Connect wires to solenoid and pressure switch assembly (Fig. 55) connector, input (Fig. 56) and out- put (Fig. 57) speed sensors, and line pressure sensor (Fig. 58). Be sure transmission harnesses are prop- erly routed.

Fig.57ConnectOutputSpeedSensor

1 - TRANSMISSION 2 - OUTPUT SPEED SENSOR

Fig.55ConnectTransmissionSolenoid

1 - TRANSMISSION 2 - TRANSMISSION SOLENOID/TRS ASSEMBLY

Fig.58ConnectLinePressureSensor

1 - TRANSMISSION 2 - LINE PRESSURE SENSOR

Fig.56ConnectInputSpeedSensor

1 - TRANSMISSION 2 - INPUT SPEED SENSOR

CAUTION: It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

(22) Install

torque converter-to-driveplate bolts.

Tighten bolts to 31 N·m (270 in. lbs.).

(23) Install starter motor and cooler line bracket. (24) Connect cooler lines to transmission. (25) Install transmission fill tube. (26) Install exhaust components, if necessary.

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(28) Align and connect propeller shaft(s). (29) Adjust gearshift cable if necessary. (30) Install any skid plates removed previously. (Refer to 13 - FRAMES & BUMPERS/FRAME/ TRANSFER CASE SKID PLATE - INSTALLATION)

(31) Lower vehicle. (32) Fill transmission with Mopart ATF +4, Auto-

matic Transmission Fluid.

(27) Install the engine collar (Fig. 59) onto the transmission and the engine. Tighten the bolts to 54
N·m (40 ft.lbs.).

Fig.59TransmissionCollar

1 - ENGINE 2 - ENGINE TO TRANSMISSION COLLAR 3 - TRANSMISSION

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HYDRAULIC SCHEMATICS

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Component

DR

Inch

Metric 0.84-1.54
mm 0.81-1.24
mm MoparT ATF +4

0.033-0.061
in. 0.032-0.049
in.

UD Clutch Pack Clearance Reverse Clutch Pack Clearance Recommended fluid

TRANSMISSION