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ASSEMBLY
CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Over- tightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recom- mended torque only.
LOWER HOUSING
(1) Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid (Fig. 307).
(2) Install 3-4 timing valve spring and valve in
lower housing.
housing.
(3) Install 3-4 quick fill valve in lower housing. (4) Install 3-4 quick fill valve spring and plug in
(5) Install timing valve end plate. Tighten end
plate screws to 4 N·m (35 in. lbs.) torque.
DR VALVE BODY (Continued)
Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged.
Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in han- dling.
The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are:
† dual solenoid and harness assembly † solenoid gasket † solenoid case connector O-rings and shoulder bolt† switch valve and spring † pressure adjusting screw and bracket assembly † throttle lever † manual lever and shaft seal † throttle lever shaft seal, washer, and E-clip † fluid filter and screws † detent ball and spring † valve body screws † governor pressure solenoid † governor pressure sensor and retaining clip † park lock rod and E-clip
21 - 478
VALVE BODY (Continued)AUTOMATIC TRANSMISSION - 48RE
DR
Fig.307LowerHousingShiftValvesandSprings
1 - 3-4 ACCUMULATOR HOUSING 2 - 3-4 SHIFT VALVE AND SPRING 3 - PLUG 4 - SPRING RETAINER 5 - CONVERTER CLUTCH VALVE AND SPRING 6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 7 - OVERDRIVE SEPARATOR PLATE 8 - CASE CONNECTOR 9 - CONVERTER CLUTCH SOLENOID 10 - OVERDRIVE SOLENOID
11 - TIMING VALVE COVER 12 - PLUG 13 - 3-4 TIMING VALVE AND SPRING 14 - LOWER HOUSING 15 - ACCUMULATOR END PLATE 16 - 3-4 ACCUMULATOR PISTON AND SPRING 17 - E-CLIP 18 - 3-4 QUICK FILL SPRING AND VALVE 19 - SOLENOID GASKET 20 - HARNESS
AUTOMATIC TRANSMISSION - 48RE
21 - 479
DR VALVE BODY (Continued) 3-4 ACCUMULATOR
(1) Lubricate accumulator piston, seals and hous- ing piston bore with clean transmission fluid (Fig. 308).
(2) Install new seal rings on accumulator piston. (3) Install piston and spring in housing. (4) Install end plate on housing.
Fig.309RearClutchAndRearServoCheckBall
Locations
1 - REAR CLUTCH CHECK BALL 2 - REAR SERVO CHECK BALL 3 - TRANSFER PLATE
Fig.3083-4AccumulatorandHousing
1 - ACCUMULATOR PISTON 2 - 3-4 ACCUMULATOR HOUSING 3 - TEFLON SEALS 4 - PISTON SPRING 5 - COVER PLATE AND SCREWS
TRANSFER PLATE
Fig.310SeparatorPlateFilterScreenInstallation 1 - UPPER HOUSING SEPARATOR PLATE 2 - FILTER SCREEN
(1) Install rear clutch and rear servo check balls in
transfer plate (Fig. 309).
(2) Install filter screen in upper housing separator
plate (Fig. 310).
(3) Align and position upper housing separator
plate on transfer plate (Fig. 311).
(4) Install brace plate (Fig. 311). Tighten brace
attaching screws to 4 N·m (35 in. lbs.) torque.
(5) Install remaining separator plate attaching screws. Tighten screws to 4 N·m (35 in. lbs.) torque.
Fig.311BracePlate
1 - BRACE 2 - TRANSFER PLATE 3 - SEPARATOR PLATE
AUTOMATIC TRANSMISSION - 48RE
21 - 480
VALVE BODY (Continued) UPPER AND LOWER HOUSING(1) Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (Fig. 312). Seven check balls are used. The single large check ball is approxi- mately 8.7 mm (11/32 in.) diameter. The single small check ball in diameter. The remaining 5 check balls are approxi- mately 6.3 mm (1/4 in.) in diameter.
is approximately 4.8 mm (3/16 in.)
(2) Position assembled transfer plate and upper housing separator plate on upper housing (Fig. 313). Be sure filter screen is seated in proper housing recess.
DR
(3) Install the Number 10 check ball
into the transfer plate (Fig. 314). The check ball is approxi- mately 4.8 mm (3/16 in.) in diameter.
(4) Position lower housing separator plate on
transfer plate (Fig. 315).
(5) Install
lower housing on assembled transfer
plate and upper housing (Fig. 316).
(6) Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 N·m (35 in. lbs.) torque. Start at center and work out to sides when tighten- ing screws (Fig. 316).
Fig.312CheckBallLocationsInUpperHousing
1 - SMALL DIAMETER CHECK BALLS (5) 2 - LARGE DIAMETER CHECK BALL (1)
Fig.314Number10CheckBall
1 - NUMBER 10 CHECK BALL (3/169)
Fig.313InstallingTransferPlateOnUpperHousing 1 - FILTER SCREEN 2 - TRANSFER PLATE/SEPARATOR PLATE ASSEMBLY 3 - UPPER HOUSING
Fig.315LowerHousingSeparatorPlate
1 - BE SURE TO ALIGN BORES 2 - TRANSFER PLATE 3 - LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
DR VALVE BODY (Continued)
AUTOMATIC TRANSMISSION - 48RE
21 - 481
UPPER HOUSING VALVE AND PLUG
Refer to (Fig. 317), (Fig. 318) and (Fig. 319) to per-
form the following steps.
(1) Lubricate valves, plugs, springs with clean
transmission fluid.
(2) Assemble regulator valve line pressure sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 N·m (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs. (4) Install 1-2 shift control valve and spring. (5) Install retainer, spring,
limit valve, and 2-3
throttle plug from limit valve housing.
(6) Install
limit valve housing and cover plate.
Tighten screws to 4 N·m (35 in. lbs.). (7) Install shuttle valve as follows:
(a) Insert plastic guides in shuttle valve second-
ary spring and install spring on end of valve.
(b) Install shuttle valve into housing. (c) Hold shuttle valve in place.
Fig.316InstallingLowerHousingOnTransferPlate
AndUpperHousing
1 - VALVE BODY SCREWS (13) 2 - LOWER HOUSING 3 - UPPER HOUSING 4 - TRANSFER PLATE
Fig.317ShuttleandBoostValveLocations
1 - SPRING 2 - RETAINER 3 - BOOST VALVE 4 - BOOST VALVE PLUG 5 - SPRING GUIDES 6 - E-CLIP 7 - SHUTTLE VALVE SECONDARY SPRING
8 - SHUTTLE VALVE COVER 9 - SHUTTLE VALVE 10 - SHUTTLE VALVE PRIMARY SPRING 11 - GOVERNOR PLUG COVER 12 - THROTTLE PLUG 13 - UPPER HOUSING 14 - BOOST VALVE COVER
21 - 482
VALVE BODY (Continued)AUTOMATIC TRANSMISSION - 48RE
DR
(d) Compress secondary spring and install E-clip
BOOST VALVE TUBE AND BRACE
in groove at end of shuttle valve.
(e) Verify that spring and E-clip are properly
seated before proceeding. (8) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N·m (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 valve governor plugs in
valve body.
(10) Install throttle plug.
shuttle valve primary spring and
(11) Align and install governor plug cover. Tighten
cover screws to 4 N·m (35 in. lbs.) torque.
(1) Position valve body assembly so lower housing
is facing upward (Fig. 320).
(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port (Fig. 320).
(4) Insert and seat each end of tube in housings. (5) Slide tube brace under tube and into alignment
with valve body screw holes (Fig. 321).
(6) Install and finger tighten three screws that secure tube brace to valve body housings (Fig. 321).
1 - UPPER HOUSING 2 - REGULATOR VALVE 3 - SWITCH VALVE 4 - REGULATOR VALVE SPRING 5 - KICKDOWN VALVE 6 - KICKDOWN DETENT 7 - THROTTLE VALVE AND SPRING
Fig.318UpperHousingControlValveLocations
8 - MANUAL VALVE 9 - 1-2 GOVERNOR PLUG 10 - GOVERNOR PLUG COVER 11 - THROTTLE PLUG 12 - 2-3 GOVERNOR PLUG 13 - SHUTTLE VALVE PRIMARY SPRING
DR VALVE BODY (Continued)
AUTOMATIC TRANSMISSION - 48RE
21 - 483
Fig.319UpperHousingShiftValveandPressurePlugLocations
1 - UPPER HOUSING 2 - 1-2 SHIFT VALVE AND SPRING 3 - 2-3 SHIFT VALVE AND SPRING 4 - 2-3 THROTTLE PLUG 5 - LIMIT VALVE HOUSING 6 - LIMIT VALVE COVER
7 - LIMIT VALVE AND SPRING 8 - RETAINER 9 - 1-2 SHIFT CONTROL VALVE AND SPRING 10 - PRESSURE PLUG COVER 11 - PLUG SLEEVE 12 - THROTTLE PRESSURE SPRING AND PLUG
Fig.320BoostValveTube
1 - BOOST VALVE TUBE 2 - LOWER HOUSING 3 - DISENGAGE THIS END OF TUBE FIRST 4 - UPPER HOUSING
Fig.321BoostValveTubeAndBrace
1 - BOOST VALVE TUBE 2 - TUBE BRACE
21 - 484
VALVE BODY (Continued)AUTOMATIC TRANSMISSION - 48RE
DR
(7) Bend tube brace tabs up and against tube to
hold it in position (Fig. 322).
(8) Tighten all valve body housing screws to 4 N·m (35 in. lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward.
Fig.322SecuringBoostValveTubeWithBrace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
3-4 ACCUMULATOR
Fig.323ConverterClutchAnd3-4ShiftValve
Springs
1 - RIGHT-SIDE SCREW 2 - 3-4 ACCUMULATOR 3 - 3-4 SHIFT VALVE SPRING 4 - CONVERTER CLUTCH VALVE SPRING
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 323).
(2) Loosely attach accumulator housing with right- side screw (Fig. 323). Install only one screw at this time as accumulator must be free to pivot upward for ease of installation.
(3) Install 3-4 shift valve and spring. (4) Install
converter
clutch timing valve and
spring.
(5) Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand.
(6) Swing accumulator housing upward over valve
springs and plug.
(7) Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated (Fig. 324). Tighten screws to 4 N·m (35 in. lbs.).
Fig.324Seating3-4AccumulatorOnLower
Housing
1 - ACCUMULATOR BOX 2 - CONVERTER CLUTCH VALVE PLUG
DR VALVE BODY (Continued) VALVE BODY FINAL
(1) Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 N·m (35
in. lbs.) torque.(2) Insert manual
lever detent spring in upper
housing.
(3) Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583 (Fig. 325).
(4) Install throttle lever in upper housing. Then lever over throttle lever and start
install manual manual lever into housing.
(5) Align manual lever with detent ball and man- ual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated.
(6) Then install manual
lever seal, washer and
E-clip.
valve.
(7) Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve (Fig. 326).
(8) Position line pressure adjusting screw in
adjusting screw bracket.
(9) Install spring on end of line pressure regulator
(10) Install switch valve spring on tang at end of
adjusting screw bracket.
(11) Install manual valve. (12) Install throttle valve and spring. (13) Install kickdown valve and detent. (14) Install pressure regulator valve. (15) Install switch valve. (16) Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 N·m (35 in. lbs.) torque.
AUTOMATIC TRANSMISSION - 48RE
21 - 485
(17) Perform Line Pressure and Throttle Pressure adjustments. (Refer to 21 - TRANSMISSION/TRANS- AXLE/AUTOMATIC/VALVE BODY - ADJUSTMENTS) (18) Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. (19) Attach solenoid case connector to 3-4 accumu- lator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumula- tor housing (Fig. 327). Seat tang in dimple before tightening connector screw.
Fig.326ManualAndThrottleLeverAlignment
1 - THROTTLE LEVER 2 - MANUAL LEVER VALVE ARM 3 - MANUAL VALVE 4 - KICKDOWN VALVE
Fig.325DetentBallSpring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig.327SolenoidHarnessCaseConnector
ShoulderBolt
1 - SOLENOID HARNESS CASE CONNECTOR 2 - 3-4 ACCUMULATOR HOUSING
DR
(3) Check condition of seals on accumulator piston.
Install new piston seals, if necessary.
(4) Verify that transmission range sensor is NOT installed. Valve body cannot be installed with sensor in place.
(5) Place valve body manual lever in low (1 posi- tion) so ball on park lock rod will be easier to install in sprag.
(6) Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case.
(7) Lubricate seal rings on valve body harness con-
nector with petroleum jelly.
(8) Position valve body in case and work end of park lock rod into and through pawl sprag. Turn pro- peller shaft to align sprag and park lock teeth if nec- essary. The rod will click as it enters pawl. Move rod to check engagement.
CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity.
(9) Install accumulator spring and piston into case. Then swing valve body over piston and outer spring to hold it in place.
(10) Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. (11) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(12) Tighten valve body bolts alternately and
evenly to 11 N·m (100 in. lbs.) torque.
(13) Install new fluid filter on valve body. Tighten
filter screws to 4 N·m (35 in. lbs.) torque.
(14) Install throttle and gearshift levers on valve
body manual lever shaft.
21 - 486
VALVE BODY (Continued)AUTOMATIC TRANSMISSION - 48RE
(20) Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 N·m (72 in. lbs.) torque. (21) Verify that solenoid wire harness is properly routed (Fig. 328). Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover.
Fig.328SolenoidHarnessRouting
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS 2 - 3-4 ACCUMULATOR COVER PLATE
GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn valve body assembly over so accumulator
side of transfer plate is facing down.
(2) Install new O-rings on governor pressure sole-
noid and sensor.
(3) Lubricate solenoid and sensor O-rings with
clean transmission fluid.
(4) Install governor pressure sensor in governor body. (5) Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. (6) Position governor body gasket on transfer plate. (7) Install retainer plate on governor body and around solenoid. Be sure solenoid connector is posi- tioned in retainer cutout.
(8) Align screw holes in governor body and trans- fer plate. Then install and tighten governor body screws to 4 N·m (35 in. lbs.) torque.
(9) Connect harness wires to governor pressure
solenoid and governor pressure sensor.
(10) Install fluid filter and pan. (11) Lower vehicle. (12) Fill transmission with recommended fluid and
road test vehicle to verify repair.
INSTALLATION
(1) Check condition of O-ring seals on valve body harness connector (Fig. 329). Replace seals on con- nector body if cut or worn.
(2) Check condition of manual
in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket (Fig. 330).
lever shaft seal
Fig.329ValveBodyHarnessConnectorO-RingSeal 1 - CONNECTOR O-RINGS 2 - VALVE BODY HARNESS CONNECTOR 3 - HARNESS
AUTOMATIC TRANSMISSION - 48RE
21 - 487
Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure.
Fig.331LinePressureAdjustment
1 - WRENCH 2 - 1–5/16 INCH
THROTTLE PRESSURE ADJUSTMENT
Insert Gauge Tool C-3763 between the throttle
lever cam and the kickdown valve stem (Fig. 332).
Push the gauge tool inward to compress the kick- down valve against the spring and bottom the throt- tle valve.
Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool.
NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment.
DR VALVE BODY (Continued)
(15) Check and adjust front and rear bands if nec-
essary.
(16) Connect solenoid case connector wires. (17) Install the transmission range sensor. (18) Install oil pan and new gasket. Tighten pan
bolts to 17 N·m (13 ft. lbs.) torque.
(19) Lower vehicle and fill
transmission with
Mopart ATF +4, Automatic Transmission fluid.
(20) Check and adjust gearshift and throttle valve
cables, if necessary.
Fig.330ManualLeverShaftSeal
1 - 15/1688 SOCKET 2 - SEAL
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
valve body;
There are two control pressure adjustments on the † Line Pressure † Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last.
LINE PRESSURE ADJUSTMENT
Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale (Fig. 331).
Distance should be 33.4 mm (1-5/16 in.). If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 in.) setting is an approximate setting. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa).
Fig.332ThrottlePressureAdjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW) 2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE LEVER AND KICKDOWN VALVE)
21 - 488
AUTOMATIC TRANSMISSION - 45RFE/545RFE
AUTOMATIC TRANSMISSION - 45RFE/545RFE
TABLE OF CONTENTS
page
DR
page
AUTOMATIC TRANSMISSION - 45RFE/545RFE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 489
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 490
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 491
DIAGNOSIS AND TESTING - PRELIMINARY . . 491
DIAGNOSIS AND TESTING - ROADTESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
DIAGNOSIS AND TESTING - HYDRAULIC
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION . . . . . . . . . . . . . . . . . . . . 541
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT . . . . . . . . . . . . . . . 542
STANDARD PROCEDURE - TRANSMISSION
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
GEARSHIFT CABLE
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 493
DIAGNOSIS AND TESTING - GEARSHIFT
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION . . . . 494
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK . . . . . . . . . . . . . . . . 495
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . 495
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 497
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 503
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 510
SCHEMATICS AND DIAGRAMSHYDRAULIC SCHEMATICS . . . . . . . . . . . . . 513
SPECIFICATIONS TRANSMISSION
SPECIAL TOOLS
. . . . . . . . . . . . . . . . . . . . . 534
RFE TRANSMISSION
. . . . . . . . . . . . . . . . . 535
4C RETAINER/BULKHEAD
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 538
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 538ADAPTER HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 539BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 540
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 540
DIAGNOSIS AND TESTING - BRAKETRANSMISSION SHIFT INTERLOCK . . . . . . 540
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK
. . . . . . . . . . . . . . . . . . . 540
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL . . . . . . . . . . . . . 541
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . 541
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 545
ADJUSTMENTSGEARSHIFT CABLE
. . . . . . . . . . . . . . . . . . 546
HOLDING CLUTCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 546
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 546INPUT CLUTCH ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 549
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 549
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 550
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 552INPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 558
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 558
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 559LINE PRESSURE (LP) SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 559
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 559
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 560LOW/REVERSE CLUTCH
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 560
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 561
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 561OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 562
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 562
STANDARD PROCEDURE - OIL PUMPVOLUME CHECK . . . . . . . . . . . . . . . . . . . . . 563
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 564
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 566
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 566DR
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 489
OIL PUMP FRONT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 567OUTPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 567
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 567
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 567OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 568
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 568
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 569PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 569
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 569PLANETARY GEARTRAIN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 571
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 571
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 573
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 573
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 573SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 574
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 574SOLENOID SWITCH VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 574
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 574SOLENOIDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 574
AUTOMATIC TRANSMISSION - 45RFE/545RFE DESCRIPTION
The 45RFE/545RFE automatic transmissions is a sophisticated, multi-range, electronically controlled transmission which combines optimized gear ratios for responsive performance, state of the art efficiency features and low NVH. Other features include driver adaptive shifting and three planetary gear sets to provide wide ratio capability with precise ratio steps for optimum driveability. The three planetary gear sets also make available a unique alternate second gear ratio. The primary 2nd gear ratio fits between 1st and 3rd gears for normal through-gear accelera- tions. The alternate second gear ratio (2prime) allows smoother 4-2 kickdowns at high speeds to provide 2nd gear passing performance over a wider highway cruising range.
The hydraulic portion of the transmission consists of the transmission fluid, fluid passages, hydraulic valves, and various line pressure control components.
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 575
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 575
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 579
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 580TRANSMISSION CONTROL RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 581
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 581TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 581
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 581TRANSMISSION SOLENOID/TRS ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 582
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 582
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 583TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 583
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 583VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 584
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 585
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 586
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 588
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 590mission consist of the following:
The primary mechanical components of the trans- † Three multiple disc input clutches † Three multiple disc holding clutches † Five hydraulic accumulators † Three planetary gear sets † Dual Stage Hydraulic oil pump † Valve body † Solenoid pack The TCM is the “heart” or “brain” of the electronic control system and relies on information from vari- ous direct and indirect inputs (sensors, switches, etc.) to determine driver demand and vehicle operating conditions. With this information, the TCM can cal- culate and perform timely and quality shifts through various output or control devices (solenoid pack, transmission control relay, etc.).
TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped on the left side of the case just above the oil pan sealing surface (Fig. 1). Refer to this information when ordering replacement parts. A label is attached to the transmission case above the stamped numbers.
21 - 490
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
The label gives additional also be necessary for identification purposes.
information which may
Fig.1TransmissionPartAndSerialNumber
Location
1 - IDENTIFICATION NUMBERS (STAMPED)
GEAR RATIOS
The 45RFE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:1
2nd Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
GEAR RATIOSThe 545RFE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:1
2nd Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.67:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1OPERATION
The 45RFE/545RFE offers full electronic control of all automatic up and downshifts, and features real- time adaptive closed-loop shift and pressure control. Electronic shift and torque converter clutch controls help protect the transmission from damage due to high temperatures, which can occur under severe operating conditions. By altering shift schedules, line pressure, and converter clutch control, these controls reduce heat generation and increase transmission cooling.
To help reduce efficiency-robbing parasitic losses, the transmissions includes a dual-stage transmission fluid pump with electronic output pressure control. Under most driving conditions, pump output pres- sure greatly exceeds that which is needed to keep the clutches applied. The 45RFE/545RFE pump-pressure control system monitors input torque and adjusts the pump pressure accordingly. The primary stage of the pump works the second stage is bypassed when demand is low. The control system also monitors input and output speed and, if incipi- ent clutch slip is observed, the pressure control sole- noid duty cycle is varied, increasing pressure in proportion to demand.
continuously;
A high-travel torque converter damper assembly allows earlier torque converter clutch engagement to reduce slippage. Needle-type thrust bearings reduce internal friction. The 45RFE/545RFE is packaged in a one-piece die-cast aluminum case. To reduce NVH, the case has high lateral, vertical and torsional stiff- ness. It is also designed to maximize the benefit of the structural dust cover that connects the bottom of the bell housing to the engine bedplate, enhancing overall power train stiffness. Dual filters protect the pump and other components. A pump return filter is added to the customary main sump filter. Indepen- dent lubrication and cooler circuits assure ample pressure for normal transmission operation even if the cooler is obstructed or the fluid cannot flow due to extremely low temperatures.
The hydraulic control system design (without elec- tronic assist) provides the transmission with PARK, REVERSE, NEUTRAL, SECOND, and THIRD gears, based solely on driver shift lever selection. This design allows the vehicle to be driven (in “limp-in” mode) in the event of a electronic control system fail- ure, or a situation that the Transmission Control Module (TCM) recognizes as potentially damaging to the transmission.
The TCM also performs certain self-diagnostic functions and provides comprehensive information (sensor data, DTC’s, etc.) which is helpful in proper diagnosis and repair. This information can be viewed with the DRBt scan tool.
DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued) DIAGNOSIS AND TESTING
VEHICLE IS DISABLED
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 491
DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION
CAUTION: Before attempting any repair on a RFE automatic transmission, check for Diagnostic Trou- ble Codes with the DRBT scan tool.
Transmission malfunctions may be caused by these general conditions: † Poor engine performance † Improper adjustments † Hydraulic malfunctions † Mechanical malfunctions † Electronic malfunctions Diagnosis of these problems should always begin by checking the easily accessible variables: fluid level and condition, gearshift cable adjustment. Then per- form a road test to determine if the problem has been corrected or if more diagnosis is necessary. If the problem persists after the preliminary tests and cor- rections are completed, hydraulic pressure checks should be performed.
DIAGNOSIS AND TESTING - PRELIMINARY
Two basic procedures are required. One procedure for vehicles that are drivable and an alternate proce- dure for disabled vehicles (will not back up or move forward).
VEHICLE IS DRIVABLE
(1) Check for transmission fault codes using DRBt
scan tool.
(2) Check fluid level and condition. (3) Adjust gearshift cable if complaint was based
on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
(5) Perform hydraulic pressure test if shift prob-
lems were noted during road test.
(6) Perform air-pressure test to check clutch oper-
ation.
(1) Check fluid level and condition. (2) Check for broken or disconnected gearshift
cable.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
(4) Raise and support vehicle on safety stands, start engine, shift transmission into gear, and note following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmis- sion is noisy, stop engine. Remove oil pan, and check for debris. If pan is clear, remove transmis- sion and check for damaged driveplate, converter, oil pump, or input shaft.
(c) If propeller shaft does not turn and transmis- sion is not noisy, perform hydraulic-pressure test to determine if problem is hydraulic or mechanical.
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testing, be sure the fluid level and con- trol cable adjustments have been checked and adjusted if necessary. Verify that all diagnostic trou- ble codes have been resolved.
Observe engine performance during the road test. A poorly tuned engine will not allow accurate analy- sis of transmission operation.
Operate the transmission in all gear ranges. Check for shift variations and engine flare which indicates slippage. Note if shifts are harsh, spongy, delayed, early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means clutch, overrunning clutch, or line pressure problems. A slipping clutch can often be determined by com- paring which internal units are applied in the vari- ous gear ranges. The Clutch Application charts provide a basis for analyzing road test results.
21 - 492
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
45RFE CLUTCH APPLICATION CHART
SLP
UD
OD
2C
4C
P–PARK
R–REVERSE N-NEUTRAL
D–OVERDRIVE
FIRST
SECOND
SECOND PRIME
THIRD FOURTH LIMP-IN 2–FIRST SECOND LIMP-IN 1–LOW
ON
ON ON ON
ON ON ON ON ON
ON
ON 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.
545RFE CLUTCH APPLICATION CHART
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 TAPTEST 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
prime3-2
3-2
prime135
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)AUTOMATIC TRANSMISSION - 45RFE/545RFE
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-3339NOTE: 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)AUTOMATIC TRANSMISSION - 45RFE/545RFE
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 GEAR5 - BEARING NUMBER 7
6 - THRUST PLATE (SELECT) 7 - BEARING NUMBER 6
8 - REACTION ANNULUSFig.27RemoveParkSpragSnap-Ring
Fig.28RemoveParkSpragGear
1 - SNAP-RING
1 - PARK SPRAG GEAR
21 - 502
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
(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).
