Connector DODGE RAM 1500 1998 2.G Workshop Manual

INSTALLATION
(1) Install the output speed sensor into the trans-
mission case.
(2) Install the bolt to hold the output speed sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the output
speed sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
TOW/HAUL OVERDRIVE
SWITCH
DESCRIPTION
The tow/haul overdrive OFF (control) switch is
located in the shift lever arm (Fig. 106). The switch
is a momentary contact device that signals the PCM
to toggle current status of the overdrive function.
OPERATION
At key-on, overdrive operation is allowed. Pressing
the switch once causes the tow/haul overdrive OFF
mode to be entered and the Tow/Haul lamp to be illu-
minated. Pressing the switch a second time causesnormal overdrive operation to be restored and the
tow/haul lamp to be turned off. The tow/haul over-
drive OFF mode defaults to ON after the ignition
switch is cycled OFF and ON. The normal position
for the control switch is the ON position. The switch
must be in this position to energize the solenoid and
allow a 3-4 upshift. The control switch indicator light
illuminates only when the tow/haul overdrive switch
is turned to the OFF position, or when illuminated
by the transmission control module.
REMOVAL
(1) Using a plastic trim tool, remove the tow/haul
overdrive off switch retainer from the shift lever (Fig.
107).
Fig. 105 Output Speed Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
Fig. 106 Tow/Haul Overdrive Off Switch
Fig. 107 Tow/Haul Overdrive Off Switch Retainer
21 - 392 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
OUTPUT SPEED SENSOR (Continued)

(2) Pull the switch outwards to release it from the
connector in the lever (Fig. 108)
INSTALLATION
NOTE: There is enough slack in the wire to pull out
the connector from the lever.
(1) Pull the connector out of the lever just enough
to grasp it.
CAUTION: Be careful not to bend the pins on the
tow/haul overdrive off switch. Use care when
installing the switch, as it is not indexed, and can
be accidentally installed incorrectly.
(2) Install the tow/haul overdrive off switch into
the connector (Fig. 109)
(3) Push the tow/haul overdrive off switch and wir-
ing into the shift lever.
(4) Install the tow/haul overdrive off switch
retainer onto the shift lever.
PISTONS
DESCRIPTION
There are several sizes and types of pistons used in
an automatic transmission. Some pistons are used to
apply clutches, while others are used to apply bands.
They all have in common the fact that they are
round or circular in shape, located within a smooth
walled cylinder, which is closed at one end and con-
verts fluid pressure into mechanical movement. The
fluid pressure exerted on the piston is contained
within the system through the use of piston rings or
seals.
OPERATION
The principal which makes this operation possible
is known as Pascal's Law. Pascal's Law can be stated
as: ªPressure on a confined fluid is transmitted
equally in all directions and acts with equal force on
equal areas.º
PRESSURE
Pressure (Fig. 110) is nothing more than force (lbs.)
divided by area (in or ft.), or force per unit area.
Given a 100 lb. block and an area of 100 sq. in. on
the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.
Fig. 108 Remove the Tow/Haul Overdrive Off Switch
Fig. 109 Install the Tow/Haul Overdrive Off SwitchFig. 110 Force and Pressure Relationship
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 393
TOW/HAUL OVERDRIVE SWITCH (Continued)

TRANSMISSION SOLENOID/
TRS ASSEMBLY
DESCRIPTION
The transmission solenoid/TRS assembly is inter-
nal to the transmission and mounted on the valve
body assembly (Fig. 126). The assembly consists of
six solenoids that control hydraulic pressure to the
six friction elements (transmission clutches), and the
torque converter clutch. The pressure control sole-
noid is located on the side of the solenoid/TRS assem-
bly. The solenoid/TRS assembly also contains five
pressure switches that feed information to the TCM.
OPERATION
SOLENOIDS
Solenoids are used to control the L/R, 2C, 4C, OD,
and UD friction elements. The reverse clutch is con-
trolled by line pressure and the position of the man-
ual valve in the valve body. All the solenoids are
contained within the Solenoid and Pressure Switch
Assembly. The solenoid and pressure switch assembly
contains one additional solenoid, Multi-Select (MS),
which serves primarily to provide 2nd and 3rd gear
limp-in operation.
The solenoids receive electrical power from the
Transmission Control Relay through a single wire.
The TCM energizes or operates the solenoids individ-
ually by grounding the return wire of the solenoid as
necessary. When a solenoid is energized, the solenoid
valve shifts, and a fluid passage is opened or closed
(vented or applied), depending on its default operat-
ing state. The result is an apply or release of a fric-
tional element.
The MS and UD solenoids are normally applied to
allow transmission limp-in in the event of an electri-
cal failure.The continuity of the solenoids and circuits are
periodically tested. Each solenoid is turned on or off
depending on its current state. An inductive spike
should be detected by the TCM during this test. If no
spike is detected, the circuit is tested again to verify
the failure. In addition to the periodic testing, the
solenoid circuits are tested if a speed ratio or pres-
sure switch error occurs.
Fig. 126 Transmission Solenoid/TRS Assembly
1 - PRESSURE CONTROL SOLENOID
2 - TRANSMISSION RANGE SELECTOR PLATE
3 - 23-WAY CONNECTOR
4 - SOLENOID PACK
5 - TRANSMISSION RANGE SENSOR
6 - VALVE BODY
21 - 406 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR

LOW/REVERSE SWITCH VALVE
The low/reverse switch valve allows the low/reverse
clutch to be operated by either the LR/CC solenoid or
the MS solenoid.
REMOVAL
The valve body can be removed for service without
having to remove the transmission assembly.
The valve body can be disassembled for cleaning
and inspection of the individual components. (Refer
to 21 - TRANSMISSION/AUTOMATIC - 45RFE/
VALVE BODY - DISASSEMBLY)
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Disconnect wires at the solenoid and pressure
switch assembly connector.
(4) Position drain pan under transmission oil pan.
(5) Remove transmission oil pan.
(6) Remove the primary oil filter from valve body.
(Fig. 132)
(7) Remove bolts attaching valve body to transmis-
sion case (Fig. 133).
(8) Lower the valve body and work the electrical
connector out of transmission case.
(9) Separate the valve body from the transmission.
DISASSEMBLY
(1) Remove the screws holding the solenoid and
pressure switch assembly to the valve body (Fig.
134). Do not remove the screws on the top of the sole-
noid and pressure switch assembly.
(2) Separate the solenoid and pressure switch
assembly from the valve body.
Fig. 132 Remove Primary Oil Filter
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 133 Valve Body Bolts
1 - VALVE BODY TO CASE BOLT (6)
Fig. 134 Solenoid and Pressure Switch Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
21 - 410 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
VALVE BODY (Continued)

Inspect all the fluid seals on the valve body (Fig.
141). Replace any seals that are cracked, distorted, or
damaged in any way. These seals pass fluid pressure
directly to the clutches. Any pressure leak at these
points, may cause transmission performance prob-
lems.
ASSEMBLY
(1) Lubricate valves, springs, and the housing
valve bores with clean transmission fluid.
(2) Install solenoid switch valve, manual valve,
and the low/reverse switch valve into the valve body.
(3) Install the retainers to hold each valve into the
valve body.
(4) Install the valve body check balls into their
proper locations.
(5) Position the transfer plate onto the valve body.
(6) Install the screws to hold the transfer plate to
the valve body. Tighten the screws to 5.6 N´m (50 in.
lbs.).
(7) Install the accumulator pistons and springs
into the valve body in the location from which they
were removed. Note that all accumulators except the
overdrive have two springs. The overdrive accumula-
tor piston has only one spring.
(8) Position the accumulator cover onto the valve
body.(9) Install the screws to hold the accumulator
cover onto the valve body. Tighten the screws to 8
N´m (70 in. lbs.).
(10) Install the TRS selector plate onto the valve
body and the manual valve.
(11) Install the solenoid and pressure switch
assembly onto the valve body.
(12) Install the screws to hold the solenoid and
pressure switch assembly onto the valve body.
Tighten the screws to 5.7 N´m (50 in. lbs.). Tighten
the screws adjacent to the arrows cast into the bot-
tom of the transfer plate first.
(13) Position the detent spring onto the valve body.
(14) Install the screw to hold the detent spring
onto the valve body. Tighten the screw to 4.5 N´m (40
in. lbs.).
(15) Install new clutch passage seals onto the
valve body, if necessary
INSTALLATION
(1) Check condition of seals on valve body and the
solenoid and pressure switch assembly. Replace seals
if cut or worn.
(2) Place TRS selector plate in the PARK position.
(3) Place the transmission in the PARK position.
(4) Lubricate seal on the solenoid and pressure
switch assembly connector with petroleum jelly.
(5) Position valve body in transmission and align
the manual lever on the valve body to the pin on the
transmission manual shift lever.
(6) Seat valve body in case and install one or two
bolts to hold valve body in place.
(7) Tighten valve body bolts alternately and evenly
to 12 N´m (105 in. lbs.) torque.
(8) 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
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(9) Place replacement filter in position on valve
body and into the oil pump.
(10) Install screw to hold filter to valve body.
Tighten screw to 4.5 N´m (40 in. lbs.) torque.
(11) Connect the solenoid and pressure switch
assembly connector.
(12) Install oil pan. Tighten pan bolts to 12 N´m
(105 in. lbs.) torque.
(13) Lower vehicle and fill transmission with
MopartATF +4.
(14) Check and adjust gearshift cable, if necessary.
Fig. 141 Valve Body Seals
1 - UNDERDRIVE ACCUMULATOR (2 SPRINGS)
2 - 4TH CLUTCH ACCUMULATOR (2 SPRINGS)
3 - 2ND CLUTCH ACCUMULATOR (2 SPRINGS)
4 - LOW REVERSE ACCUMULATOR (2 SPRINGS)
5 - LOW/REVERSE PASSAGE SEAL
6 - 2ND CLUTCH PASSAGE SEAL
7 - 4TH CLUTCH PASSAGE SEAL
8 - OVERDRIVE ACCUMULATOR (1 SPRING)
21 - 414 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
VALVE BODY (Continued)

Condition Possible Cause Correction
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Mark front and rear propeller shafts for assem-
bly reference.(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
DRTRANSFER CASE - NV241 GENII 21 - 417
TRANSFER CASE - NV241 GENII (Continued)

REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(2) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess could be
displaced into output bearing.
(3) Align and install rear extension on retainer
(Fig. 80).
(4) Apply MopartSilicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 N´m (12-18 ft. lbs.) torque.
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.
(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV241 GENII
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -
Fig. 80 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
21 - 438 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1124-1243
2 4H 650-719
3 NEUTRAL 389-431
4 4L 199-221
5 NOT USED 57-64
REMOVAL
(1) Raise and support the vehicle.
(2) Disengage the transfer case position sensor
connector from the position sensor.
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into
the transfer case. Torque the sensor to 20-34 N´m
(15-25 ft.lbs.).
(3) Engage the transfer case position sensor con-
nector to the position sensor.
(4) Lower vehicle.
(5) Verify proper sensor operation.
Fig. 87 Position Sensor Linear Movement
1 - POSITION 1 - 10mm  0.5mm
2 - POSITION 2 - 12mm  0.5mm
3 - POSITION 3 - 14mm  0.5mm
4 - POSITION 4 - 16mm  0.5mm
5 - POSITION 5 - 18mm  0.5mm
6 - POSITION 6 - 20mm 0.5mm - FULL EXTENSION
DRTRANSFER CASE - NV241 GENII 21 - 443
POSITION SENSOR (Continued)

REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Mark front and rear propeller shafts for assem-
bly reference.
(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
COMPANION FLANGE AND EXTENSION HOUSING
(1) Install two bolts 180É apart into the front out-
put shaft companion flange.
(2) Place holder over the bolts and against the
companion flange (Fig. 3).
(3) Remove and discard the front companion flange
nut.
(4) Remove the companion flange from the front
output shaft. It may be necessary to use Flange
puller 8992 to remove the companion flange.
(5) Use a suitable chisel or pry tool to remove the
rear extension housing dust boot (Fig. 4).
(6) Use a suitable chisel or pry tool to remove the
rear extension housing seal.
Fig. 3 Remove Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
Fig. 4 Remove Extension Housing Dust Boot
1 - EXTENSION HOUSING
2 - DUST BOOT
21 - 450 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(7) Install the front companion flange onto the
front output shaft.
(8) Install two bolts 180É apart into the front out-
put shaft companion flange.
(9) Place holder over the bolts and against the
companion flange (Fig. 90).
(10) Install a new front companion flange nut.
Tighten the companion flange nut to 176-271 N´m
(130-200 ft.lbs.).
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV271
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-25 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 15-25 -
Nut, Companion Flange 176-271 130-200 -
Fig. 90 Install Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
DRTRANSFER CASE - NV271 21 - 473
TRANSFER CASE - NV271 (Continued)