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(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
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
(9) Install a new dipstick tube seal using Seal
Installer 8254 (Fig. 34).
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Fig.34InstallDipstickTubeSealUsingTool8254
1 - TOOL 8254
2 - SEAL1 - 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.
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(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.
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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 GEAR5 - BEARING NUMBER 7
6 - THRUST PLATE (SELECT) 7 - BEARING NUMBER 6
8 - REACTION ANNULUSDR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
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(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 121 - 508
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
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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-3339Fig.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
DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued) SCHEMATICS AND DIAGRAMS
AUTOMATIC TRANSMISSION - 45RFE/545RFE
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HYDRAULIC SCHEMATICS
21 - 514
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued) SPECIFICATIONSComponent
DR
Inch
Metric 0.84-1.54
mm 0.81-1.24
mm MoparT ATF +40.033-0.061
in. 0.032-0.049
in.UD Clutch Pack Clearance Reverse Clutch Pack Clearance Recommended fluid
TRANSMISSION
GENERAL
Component
Output Shaft End Play
Input Shaft End Play
2C Clutch Pack Clearance 4C Clutch Pack Clearance L/R Clutch Pack Clearance OD Clutch Pack Clearance
Metric 0.22-0.55
mm 0.46-0.89
mm 0.455-1.335
mm 0.770-1.390
mm 1.00-1.74
mm 1.103-1.856
mmInch
0.009-0.021
in. 0.018-0.035
in. 0.018-0.053
in. 0.030-0.055
in. 0.039-0.069
in. 0.043-0.073
in.GEAR RATIOS
1ST 2ND
2ND Prime
3RD 4TH 5TH
REVERSE
TORQUE SPECIFICATIONS
DESCRIPTION
Fitting, cooler line at trans
Bolt, torque convertor Bolt/nut, crossmember
Bolt, driveplate to crankshaft
Bolt, oil pan
Screw, primary fluid filter
Bolt, oil pump
Bolt, oil pump body to cover Screw, plate to oil pump body
Bolt, valve body to case Plug, pressure test port
Bolt, reaction shaft support
Screw, valve body to transfer plate
Screw, solenoid module to transfer plate
Screw, accumulator cover
Screw, detent spring
Bolt, input speed sensor Bolt, output speed sensor Bolt, line pressure sensor Bolt, extension housing
Valve, cooler return filter bypass
Screw, manual valve cam retaining
Bolt, manual lever
N·m 17.5
31
68
75
11.8
4.5
28.2
4.5
4.5
11.8
5.1
11.8
5.6
5.7
4.5
4.5
11.8
11.8
11.8
54
4.5
4.5
28.2Ft. Lbs.
23
50
55
403.00:1
1.67:1
1.50:1
1.0:1
0.75:1
0.67:1
3.00:1In. Lbs.
155
105
40
250
40
40
105
45
105
50
50
40
40
105
105
10540
40
250DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued) SPECIAL TOOLS
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 535
RFE TRANSMISSION
Gauge,OilPressure-C-3292
Compressor,Spring-8249
Gauge,OilPressure-C-3293SP
Compressor,Spring-8250
DialIndicator-C-3339
Installer,Seal-C-3860-A
Compressor,Spring-8251
Installer,Piston-8252
21 - 536
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Installer,Seal-8253
Adapter,PressureTap-8258-A
Installer,Seal-8254
Adapter,LinePressure-8259
Installer,Snap-ring-8255
Fixture,InputClutchPressure-8260
Stand,Support-8257
Plate,Alignment-8261
DR AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 537
EndPlaySet-8266
Wrench,Filter-8321
Compressor,Spring-8285
Installer,Piston-8504
Installer,Bearing-8320
21 - 538
AUTOMATIC TRANSMISSION - 45RFE/545RFE
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4C RETAINER/BULKHEAD DISASSEMBLY
(7) Remove the 4C piston return spring and piston from the retainer/bulkhead (Fig. 60). Use 20 psi of air pressure to remove the piston if necessary.
(1) Remove the 2C piston belleville spring snap-
ring from the 4C retainer /bulkhead (Fig. 60).
(2) Remove the 2C piston Belleville spring from
the retainer/bulkhead (Fig. 60).
(3) Remove the 2C piston from the retainer/bulk- head. Use 20 psi of air pressure to remove the piston if necessary.
(4) Remove the 4C clutch snap-ring from the
retainer/bulkhead (Fig. 60).
(5) Remove the 4C clutch pack from the retainer/
bulkhead (Fig. 60).
(6) Using Spring Compressor 8250 and a suitable shop press, compress the 4C piston return spring and remove the snap-ring (Fig. 60).
ASSEMBLY
(1) Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.
(2) Install new seals on the 2C and 4C pistons
(Fig. 60).
to installation.
head (Fig. 60).
4C piston.
(3) Lubricate all seals with Mopart ATF +4 prior
(4) Install the 4C piston into the 4C retainer/bulk-
(5) Position the 4C piston return spring onto the
1 - SEAL 2 - 2C PISTON 3 - PLATE 4 - DISC 5 - 2C BELLEVILLE SPRING 6 - SNAP-RING 7 - SNAP-RING (SELECT)
Fig.604CRetainer/BulkheadComponents
8 - REACTION PLATE 9 - SNAP-RING 10 - RETURN SPRING 11 - SEAL 12 - 4C PISTON 13 - 4C RETAINER/BULKHEAD
DR 4C RETAINER/BULKHEAD (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 539
(6) Using Spring Compressor 8250 and a suitable shop press, compress the 4C piston return spring and install the snap-ring (Fig. 61).
Fig.61Compress4CPistonReturnSpringUsing
Tool8250
1 - PRESS 2 - TOOL 8250
(7) Assemble and install the 4C clutch pack into the retainer/bulkhead (Fig. 60) with the steel separa- tor plate against the piston.
(8) Install the 4C reaction plate and snap-ring into the retainer/bulkhead (Fig. 60). The 4C reaction plate is non-directional.
(9) Measure the 4C clutch clearance. The correct clutch clearance is 0.77-1.39 mm (0.030-0.055 in.). The snap-ring is selectable. Install the chosen snap- ring and re-measure to verify the selection.
(10) Install the 2C piston into the retainer/bulk-
head (Fig. 60).
piston.
(11) Position the 2C Belleville spring onto the 2C
(12) Position the 2C Belleville spring snap-ring
onto the 2C Belleville spring (Fig. 60).
(13) Using Spring Compressor 8249 and a suitable shop press (Fig. 62), compress the belleville spring until the snap-ring is engaged with the snap-ring groove in the retainer/bulkhead.
ADAPTER HOUSING SEAL REMOVAL
(1) Remove the transfer case from the transmis-
sion.
(2) Using a screw mounted on a slide hammer,
remove the adapter housing seal.
Fig.62Compress2CBellevilleSpringUsingTool
8249
1 - PRESS 2 - TOOL 8249
INSTALLATION
(1) Clean the adapter seal bore in the adapter housing of any residue or particles remaining from the original seal.
(2) Install new oil seal
in the adapter housing using Seal Installer C-3860-A (Fig. 63). A properly installed seal is flush to the face of the seal bore.
Fig.63AdapterHousingSealInstallation
1 - TOOL C-3860-A
(3) Install the transfer case onto the transmission.
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BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM DESCRIPTION
The Brake Transmission Shifter Interlock (BTSI) (Fig. 64), is a solenoid operated system. It consists of a solenoid permanently mounted on the gearshift cable.
Fig.64BrakeTransmissionInterlockMechanism 1 - STEERING COLUMN 2 - GEARSHIFT CABLE 3 - GEARSHIFT CABLE LOCK TAB 4 - BTSI SOLENOID LOCK TAB 5 - BTSI CONNECTOR
OPERATION
The system locks the shifter into the PARK posi- tion. The interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY posi- tion. An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed approximately one-half an inch. A magnetic holding device in line with the park lock cable is energized when the ignition is in the RUN position. When the key is in the RUN position and the brake pedal is depressed, the shifter is unlocked and will move into any position. The inter- lock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position, unless the shifter is fully locked into the PARK posi- tion.
DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK
(1) Verify that the key can only be removed in the
PARK position
(2) When the shift lever is in PARK And the shift handle pushbutton is in the “OUT” position, the igni- tion key cylinder should rotate freely from OFF to
LOCK. When the shifter is in any other gear or neu- tral position, the ignition key cylinder should not rotate to the LOCK position.
(3) Shifting out of PARK should not be possible when the ignition key cylinder is in the OFF posi- tion.
(4) Shifting out of PARK should not be possible while applying normal pushbutton force and ignition key cylinder is in the RUN or START positions unless the foot brake pedal is depressed approxi- mately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions.
(6) Shifting between any gears, NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch in RUN or START posi- tions.
ADJUSTMENTS - BRAKE TRANSMISSION SHIFT INTERLOCK
Correct cable adjustment is important to proper interlock operation. The gearshift cable must be cor- rectly adjusted in order to shift out of PARK.
ADJUSTMENT PROCEDURE
(1) Remove the steering column trim as necessary for access to the brake transmission shift interlock. (2) Shift the transmission into the PARK position. (3) Pull upward on both the BTSI lock tab and the
gearshift cable lock tab (Fig. 65).
(4) Verify that the shift lever is in the PARK posi-
tion.
(5) Verify positive engagement of the transmission park lock by attempting to rotate the propeller shaft. The shaft will not rotate when the park lock is engaged.
(6) Turn ignition switch to LOCK position. Be sure ignition key cylinder is in the LOCK posi- tion. Cable will not adjust correctly in any other position.
(7) Ensure that the cable is free to self-adjust by
pushing cable rearward and releasing.
(8) Push the gearshift cable lock tab down until it
snaps in place.
(9) Locate the BTSI alignment hole in the bottom of the BTSI mechanism between the BTSI lock tab and the BTSI connector.
(10) Move the BTSI assembly up or down on the gearshift cable until an appropriate size drill bit can be inserted into the alignment hole and through the assembly.
(11) Push the BTSI lock tab down until it snaps
into place and remove the drill bit.
(12) Install any steering column trim previously
removed.
DR BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 541
† NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Trans- mission shall not be able to shift from neutral to reverse.
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxi- dation and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can eas- ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
(1) Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure.
(2) A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usu- ally the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines.
(3) Heavy duty operation with a vehicle not prop- erly equipped for this type of operation. Trailer tow- ing or similar high load operation will overheat the transmission fluid if improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling sys- tem, and the engine/axle ratio combination needed to handle heavy loads.
the vehicle is
DIAGNOSIS AND TESTING - FLUID CONTAMINATION
result of:
Transmission fluid contamination is generally a † adding incorrect fluid † failure to clean dipstick and fill tube when † engine coolant entering the fluid
checking level
Fig.65BrakeTransmissionInterlockMechanism 1 - STEERING COLUMN 2 - GEARSHIFT CABLE 3 - GEARSHIFT CABLE LOCK TAB 4 - BTSI SOLENOID LOCK TAB 5 - BTSI CONNECTOR
BTSI FUNCTION CHECK
(1) Verify removal of ignition key allowed in PARK
position only.
(2) When the shift lever is in PARK, the ignition key cylinder should rotate freely from off to lock. When the shifter is in any other position, the ignition key should not rotate from off to lock.
(3) Shifting out of PARK should be possible when
the ignition key cylinder is in the off position.
(4) Shifting out of PARK should not be possible while applying normal force, and ignition key cylin- der is in the run or start positions, unless the foot brake pedal is depressed approximately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible when the ignition key cylinder is in the accessory or lock position.
(6) Shifting between any gear and NEUTRAL, or PARK, may be done without depressing foot brake with ignition switch in run or start positions.
(7) Engine starts must be possible with shifter lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any position other than PARK or NEUTRAL.
(8) With shifter lever in the: † PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. † PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. † NEUTRAL position - Normal position. Engine
starts must be possible.
AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
21 - 542
FLUID AND FILTER (Continued) † internal failure that generates debris † overheat that generates sludge (fluid break- down)† failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only.The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdraw- ing the dipstick.
Engine coolant in the transmission fluid is gener- ally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is neces- sary because normal converter flushing procedures will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL CHECK
Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly.
Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same condi- tions which occur with a low fluid level.
In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mis- taken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle
on level ground. At normal operating temperature (approximately 82 C. or 180 F.), the fluid level is cor- rect if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approx- imately at the upper COLD hole of the dipstick at 70° F fluid temperature.
NOTE: Engine and Transmission should be at nor- mal operating temperature before performing this procedure.
(1) Start engine and apply parking brake. (2) Shift the transmission into DRIVE for approxi-
mately 2 seconds.
(3) Shift
the transmission into REVERSE for
approximately 2 seconds.
(4) Shift the transmission into PARK. (5) Hook up DRBt scan tool and select transmis-
sion.
(6) Select sensors. (7) Read the transmission temperature value. (8) Compare the fluid temperature value with the
chart. (Fig. 66)
(9) Adjust transmission fluid level shown on the
dipstick according to the chart.
NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level.
(10) Check transmission for leaks.
STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT
For proper service intervals (Refer to LUBRICA- TION & MAINTENANCE/MAINTENANCE SCHED- ULES - DESCRIPTION).
REMOVAL
(1) Hoist and support vehicle on safety stands. (2) Place a large diameter shallow drain pan
beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to
transmission.
sion.
(4) Loosen bolts holding rear of pan to transmis-
(5) Slowly separate front of pan away from trans-
mission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolts hold-
ing pan to transmission.
(7) While holding pan level, lower pan away from
(8) Pour remaining fluid in pan into drain pan. (9) Remove screw holding filter to valve body (Fig.
transmission.
67).
DR FLUID AND FILTER (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 543
Fig.66TransmissionFluidTemperatureChart
(10) Separate filter from valve body and oil pump
and pour fluid in filter into drain pan.
(11) Remove and discard the oil filter seal from the
bottom of the oil pump.
(12) If replacing the cooler return filter, use Oil Filter Wrench 8321 to remove the filter from the transmission.
(13) Dispose of used trans fluid and filter(s) properly.
INSPECTION
Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis section of this group.
CLEANING
(1) Using a suitable solvent, clean pan and magnet. (2) Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan.
INSTALLATION
(1) 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.
Fig.67TransmissionFilters-4X4Shown
1 - PRIMARY OIL FILTER 2 - COOLER RETURN FILTER 3 - COOLER RETURN FILTER BYPASS VALVE 4 - VALVE BODY
CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result.
21 - 544
FLUID AND FILTER (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
(2) Place replacement filter in position on valve
body and into the oil pump.
(3) Install screw to hold filter to valve body (Fig.
67). Tighten screw to 4.5 N·m (40 in. lbs.) torque.
(4) Install new cooler return filter onto the trans- mission, if necessary. Torque the filter to 14.12 N·m (125 in.lbs.).
(5) Place bead of Mopart RTV sealant onto the
transmission case sealing surface.
(6) Place pan in position on transmission. (7) Install bolts to hold pan to transmission.
Tighten bolts to 11.8 N·m (105 in. lbs.) torque.
(8) Lower vehicle and fill
transmission with
Mopart ATF +4.
STANDARD PROCEDURE - TRANSMISSION FILL
To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: in
(1) Remove dipstick and insert clean funnel
transmission fill tube.
+4 to transmission:
(2) Add following initial quantity of Mopart ATF
(a) If only fluid and filter were changed, add 10
pints (5 quarts) of ATF +4 to transmission.
(b) If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmis- sion. (3) Check the transmission fluid (Refer to 21 - TRANSMISSION/AUTOMATIC - RFE/FLUID - STANDARD PROCEDURE) and adjust as required.
GEARSHIFT CABLE DIAGNOSIS AND TESTING - GEARSHIFT CABLE
(1) Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position.
(2) With the shift lever in the:
(a) PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible.
(b) PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.
(d) NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse.
REMOVAL
(1) Shift transmission into PARK. (2) Raise vehicle. (3) Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket (Fig. 68) or (Fig. 69).
Fig.68GearshiftCableatTransmission-RFE
1 - GEARSHIFT CABLE 2 - RFE TRANSMISSION 3 - MANUAL LEVER
Fig.69GearshiftCableatTransmission-RE
1 - GEARSHIFT CABLE 2 - RE TRANSMISSION 3 - MANUAL LEVER
DR GEARSHIFT CABLE (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 545
(4) Lower the vehicle. (5) Remove the dash panel insulation pad as nec- essary to access the gearshift cable grommet (Fig. 70).
(6) Remove grommet from the dash panel. (7) Remove any steering column trim necessary to
access the gearshift cable and BTSI mechanism.
(8) Disconnect the BTSI wiring connector. (9) Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle (Fig. 71).
INSTALLATION
(1) Route the transmission end of the gearshift cable through the opening in the dash panel (Fig. 72).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column bracket so the retaining ears (Fig. 73) are engaged and snap the cable eyelet onto the shift lever ball stud.
Fig.70GearshiftCableattheDashPanel
1 - GEARSHIFT CABLE 2 - GROMMET
Fig.72GearshiftCableattheDashPanel
1 - GEARSHIFT CABLE 2 - GROMMET
Fig.71GearshiftCableatSteeringColumn
1 - STEERING COLUMN 2 - GEARSHIFT CABLE 3 - GEARSHIFT CABLE LOCK TAB 4 - BTSI SOLENOID LOCK TAB 5 - BTSI CONNECTOR
(10) Remove gearshift cable from vehicle.
Fig.73GearshiftCableatSteeringColumn
1 - STEERING COLUMN 2 - GEARSHIFT CABLE 3 - GEARSHIFT CABLE LOCK TAB
