ECU DODGE RAM 2003 Service Repair Manual

(5) Tap old cam out of case with pin punch. Insert
punch through bolt holes at rear of case (Fig. 186).
Alternate position of punch to avoid cocking cam dur-
ing removal.
(6) Clean clutch cam bore and case. Be sure to
remove all chips/shavings generated during cam
removal.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
low-reverse drum, and overdrive piston retainer in
solvent. Dry them with compressed air after clean-
ing.
INSPECTION
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring
assembly if any rollers or springs are worn or dam-
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse drum if the clutch race,
roller surface or inside diameter is scored, worn or
damaged.Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Examine the overdrive piston retainer carefully for
wear, cracks, scoring or other damage. Be sure the
retainer hub is a snug fit in the case and drum.
Replace the retainer if worn or damaged.
ASSEMBLY
(1) Temporarily install overdrive piston retainer in
case. Use 3-4 bolts to secure retainer.
(2) Align and start new clutch cam in the trans-
mission case. Be sure serrations on cam and in caseare aligned (Fig. 187). Then tap cam into case just
enough to hold it in place.
(3) Verify that cam is correctly positioned before
proceeding any further. Narrow ends of cam ramps
should be to left when cam is viewed from front end
of case (Fig. 187).
(4) Insert Adapter Tool SP-5124 into piston
retainer (Fig. 188).
Fig. 187 Positioning Replacement Clutch Cam In
Case
1 - ALIGN SERRATIONS ON CAM AND IN CASE
2 - CLUTCH CAM
Fig. 188 Positioning Adapter Tool In Overdrive
Piston Retainer
1 - PISTON RETAINER
2 - SPECIAL TOOL SP-5124
Fig. 186 Overrunning Clutch Cam
1 - PIN PUNCH
2 - REAR SUPPORT BOLT HOLES
21 - 416 AUTOMATIC TRANSMISSION - 48REDR
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

(5) Assemble Puller Bolt SP-3701 and Press Plate
SP-3583-A (Fig. 189).
(6) Install assembled puller plate and bolt (Fig.
190). Insert bolt through cam, case and adapter tool.
Be sure plate is seated squarely on cam.
(7) Hold puller plate and bolt in place and install
puller nut SP-3701 on puller bolt (Fig. 191).
(8) Tighten puller nut to press clutch cam into
case (Fig. 191). Be sure cam is pressed into case
evenly and does not become cocked.
(9) Remove clutch cam installer tools.
(10) Stake case in 14 places around clutch cam to
help secure cam in case. Use blunt punch or chisel to
stake case.
(11) Remove piston retainer from case. Cover
retainer with plastic sheeting, or paper to keep it
dust free.
(12) Clean case and cam thoroughly. Be sure any
chips/shavings generated during cam installation are
removed from case.
Fig. 189 Assembling Clutch Cam Puller Bolt And
Press Plate
1 - PULLER BOLT SP-3701
2 - PRESS PLATE SP-3583-A
Fig. 190 Positioning Puller Plate On Clutch Cam
1 - SPECIAL TOOL SP-3701
2 - BE SURE PLATE SP-3583-A IS SEATED SQUARELY ON CAM
Fig. 191 Pressing Overrunning Clutch Cam Into
Case
1 - SPECIAL TOOL SP-3583-A
2 - TIGHTEN NUT TO DRAW CAM INTO CASE (NUT IS PART OF
BOLT SP-3701)
3 - SPECIAL TOOL SP-5124
4 - SPECIAL TOOL SP-3701
DRAUTOMATIC TRANSMISSION - 48RE 21 - 417
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

ASSEMBLY
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly to lubricate intermediate shaft bushing surfaces,
thrust washers and thrust plates and to hold these
parts in place during assembly.
(2) Install front snap-ring on sun gear and install
gear in driving shell. Then install thrust plate over
sun gear and against rear side of driving shell (Fig.
207). Install rear snap-ring to secure sun gear and
thrust plate in driving shell. Note that the large ID
chamfer on the sun gear goes forward.
(3) Install rear annulus gear on intermediate shaft
(Fig. 208).(4) Install thrust washer to rear planetary gear
(Fig. 209) using petroleum jelly. Be sure washer is
seated against corner witht teh tabs completely in
the locating holes.
(5) Install rear planetary gear in rear annulus
gear (Fig. 210). Be sure planetary carrier is seated
against annulus gear.
Fig. 207 Sun Gear Installation
1 - DRIVING SHELL
2 - SUN GEAR
3 - THRUST PLATE
4 - SUN GEAR REAR RETAINING RING
Fig. 208 Installing Rear Annulus Gear On
Intermediate Shaft
1 - REAR ANNULUS GEAR
2 - OUTPUT SHAFT
Fig. 210 Installing Rear Planetary Gear
1 - REAR ANNULUS GEAR
2 - REAR PLANETARY GEAR
Fig. 209 Installing Rear Annulus Thrust Washer
1 - REAR ANNULUS GEAR
2 - THRUST WASHER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 423
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

STATOR
Torque multiplication is achieved by locking the
stator's over-running clutch to its shaft (Fig. 240).
Under stall conditions the turbine is stationary and
the oil leaving the turbine blades strikes the face of
the stator blades and tries to rotate them in a coun-
terclockwise direction. When this happens the over-
running clutch of the stator locks and holds the
stator from rotating. With the stator locked, the oil
strikes the stator blades and is redirected into a
ªhelpingº direction before it enters the impeller. This
circulation of oil from impeller to turbine, turbine to
stator, and stator to impeller, can produce a maxi-
mum torque multiplication of about 1.75:1. As the
turbine begins to match the speed of the impeller, the
fluid that was hitting the stator in such as way as to
cause it to lock-up is no longer doing so. In this con-
dition of operation, the stator begins to free wheel
and the converter acts as a fluid coupling.
TORQUE CONVERTER CLUTCH (TCC)
The torque converter clutch is hydraulically
applied or released when fluid is feed or vented from
the hydraulic circuit by the torque converter control
(TCC) solenoid on the valve body. The torque con-
verter clutch is controlled by the Powertrain Control
Module (PCM). The torque converter clutch engages
in fourth gear, and in third gear under various con-
ditions, such as when the O/D switch is OFF, or
when the vehicle is cruising on a level surface after
the vehicle has warmed up. The torque converterclutch may disengage momentarily when an increase
in engine load is sensed by the PCM, such as when
the vehicle begins to go uphill or the throttle pres-
sure is increased.
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate oil pump seal lip with transmission
fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 241). Surface of converter lugs
should be 19mm (0.75 in.) to the rear of the straight-
edge when converter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle.
Fig. 240 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
DRAUTOMATIC TRANSMISSION - 48RE 21 - 439
TORQUE CONVERTER (Continued)

(12) Lower valve body, rotate valve body away
from case, pull park rod out of sprag, and remove
valve body (Fig. 276).
DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Disconnect wires from governor pressure sen-
sor and solenoid.
(2) Remove screws attaching governor body and
retainer plate to transfer plate.
(3) Remove retainer plate, governor body and gas-
ket from transfer plate.
(4) Remove governor pressure sensor from gover-
nor body.(5) Remove governor pressure solenoid by pulling
it straight out of bore in governor body. Remove and
discard solenoid O-rings if worn, cut, or torn.
(6) Remove small shoulder bolt that secures sole-
noid harness case connector to 3-4 accumulator hous-
ing (Fig. 277). Retain shoulder bolt. Either tape it to
harness or thread it back into accumulator housing
after connector removal.
(7) Unhook overdrive/converter solenoid harness
from 3-4 accumulator cover plate (Fig. 278).
Fig. 277 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
2 - 3-4 ACCUMULATOR HOUSING
Fig. 278 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
Fig. 276 Valve Body
1 - VALVE BODY
2 - WIRE HARNESS
3 - PARK ROD
4 - GOVERNOR PRESSURE SOLENOID
5 - GOVERNOR PRESSURE SENSOR
DRAUTOMATIC TRANSMISSION - 48RE 21 - 465
VALVE BODY (Continued)

(8) Turn valve body over and remove screws that
attach overdrive/converter solenoid assembly to valve
body (Fig. 279).
(9) Remove solenoid and harness assembly from
valve body (Fig. 280).
(10) Remove boost valve cover (Fig. 281).
(11) Remove boost valve retainer, valve spring and
boost valve (Fig. 282).
(12) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 283).
Fig. 283 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 279 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 280 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 281 Boost Valve Cover Location
1 - BOOST VALVE HOUSING AND COVER
2 - BOOST VALVE TUBE
Fig. 282 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
21 - 466 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

VALVE BODY UPPER HOUSING
(1) Note location of check balls in valve body upper
housing (Fig. 301). Then remove the one large diam-
eter and the five smaller diameter check balls.
(2) Remove governor plug and shuttle valve covers
(Fig. 303).
(3) Remove E-clip that secures shuttle valve sec-
ondary spring on valve stem (Fig. 302).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 303).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
(6) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 290).
(7) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 304).
(8) Remove limit valve housing. Then remove
retainer, spring, limit valve, and 2-3 throttle plug
from limit valve housing (Fig. 304).
(9) Remove 1-2 shift control valve and spring (Fig.
304).
(10) Remove 1-2 shift valve and spring (Fig. 304).
(11) Remove 2-3 shift valve and spring from valve
body (Fig. 304).
(12) Remove pressure plug cover (Fig. 304).
(13) Remove line pressure sleeve, throttle pressure
plug and spring (Fig. 304).
Fig. 301 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (5)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 302 Shuttle Valve E-Clip And Secondary Spring
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
21 - 472 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

(d) Compress secondary spring and install E-clip
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 shuttle valve primary spring and
throttle plug.
(11) Align and install governor plug cover. Tighten
cover screws to 4 N´m (35 in. lbs.) torque.BOOST VALVE TUBE AND BRACE
(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).
Fig. 318 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
21 - 482 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

(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.
3-4 ACCUMULATOR
(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. 322 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
Fig. 323 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
3 - 3-4 SHIFT VALVE SPRING
4 - CONVERTER CLUTCH VALVE SPRING
Fig. 324 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
21 - 484 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

(16) Disconnect gearshift cable from transmission
manual valve lever (Fig. 13).
(17) Disconnect the transmission vent hose from
the transmission.
(18) Support rear of engine with safety stand or
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.(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. 13 Gearshift Cable at Transmission - RFE
1 - GEARSHIFT CABLE
2 - RFE TRANSMISSION
3 - MANUAL LEVER
Fig. 14 Remove Transmission
1 - ENGINE
2 - TRANSMISSION
Fig. 15 Remove Input, Output, and Line Pressure
Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 497
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)