Overdrive DODGE RAM 1500 1998 2.G User Guide

TRANSMISSION RANGE SENSOR-6WAY
CAV CIRCUIT FUNCTION
1 L10 18WT/GY FUSED IGNITION SWITCH OUTPUT (RUN)
2 T117 20DG/YL TRANS RANGE SENSOR ELECTRONIC CLUSTER 5
VOLT SUPPLY
3- -
4 L1 18WT/LG BACKUP LAMP FEED
5 T917 20YL/TN TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX
6 T41 20YL/DB PARK NEUTRAL POSITION SWITCH SENSE (T41)
6 T41 18YL/DB PARK NEUTRAL POSITION SWITCH SENSE (T41)
TRANSMISSION SOLENOID ASSEMBLY (48RE)-8WAY
CAV CIRCUIT FUNCTION
1 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
2 F856 18YL/PK 5 VOLT SUPPLY
3 K900 20DB/DG SENSOR GROUND
3 K900 18DB/DG SENSOR GROUND
4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL
5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL
6 T9 18DG/TN 3-4 SHIFT SOLENOID
7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL
8 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
TRANSMISSION SOLENOID/TRS ASSEMBLY (NGC) - 23 WAY
CAV CIRCUIT FUNCTION
1 L10 18WT/GY FUSED IGNITION SWITCH OUTPUT (RUN)
2 T20 18DG/WT L/R SOLENOID CONTROL
3- -
4 T41 20YL/DB TRS T41 SENSE
5 T42 18DG/YL TRS T42 SENSE
6 L1 18WT/LG BACKUP LAMP FEED
7 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
8 T3 18DG/DB TRS T3 SENSE
9 T1 18DG/LB TRS T1 SENSE
10 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
11 T48 18BR/YL 4C PRESSURE SWITCH SENSE
12 T140 18YL/GY PRESSURE CONTROL SOLENIOD CONTROL
13 T4 18DG/LB TRS T2 SENSE
14 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
15 T147 18DG/YL 2C PRESSURE SWITCH SENSE
16 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
17 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
18 T29 18YL/WT UNDERDRIVE PRESSURE SWITCH SENSE
19 T259 18YL/DG 4C SOLENOID CONTROL
20 T219 18YL/LG 2C SOLENOID CONTROL
21 T118 18DG MS SOLENOID CONTROL
22 K900 18DB/DG SENSOR GROUND
23 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
8W - 80 - 102 8W-80 CONNECTOR PIN-OUTSDR

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Mode Door Actuator 2 BK Right Side of HVAC N/S
Multi-Function Switch BK On Steering Column 31
Natural Vacuum Leak Detection
AssemblyBK Rear of Transmission 18, 50
Output Speed Sensor DB Left Side of Transmission 11, 14, 15, 16
Overdrive Switch WT Center of Instrument Panel 35
Overhead Map/Reading Lamp
(Except Base)NAT Center of Headliner N/S
Oxygen Sensor 1/1 Upstream BK Left Front of Side of Transmission 15, 16, 17, 19
Oxygen Sensor 1/2 Downstream NAT Left Rear of Side of Transmission 15, 16, 17, 19
Oxygen Sensor 2/1 Upstream BK Right Front Side of Transmission 15, 17, 18
Oxygen Sensor 2/2 Downstream BK Right Rear Side of Transmission 15, 17, 18
Park Brake Switch At Park Brake 22, 24
Park/Turn Signal Lamp-Left Front BK At Lamp 23, 28, 29
Park/Turn Signal Lamp-Right Front BK At Lamp 1, 21, 26
Passenger Airbag On/Off Switch Right Side of Instrument Panel 33, 35, 39
Passenger Blend Door Actuator
(Dual Zone)BK Right Side of HVAC N/S
Passenger Lumbar Switch At Passenger Seat N/S
Power Mirror-Left BK At Mirror 41
Power Mirror-Right BK At Mirror 42
Power Outlet RD Center of Instrument Panel 35
Power Outlet-Console BK Center of Instrument Panel N/S
Power Seat Motor-Driver Front
VerticalRD At Driver Seat N/S
Power Seat Motor-Driver Horizontal BK At Driver Seat N/S
Power Seat Motor-Driver Rear
VerticalBK At Driver Seat N/S
Power Seat Switch-Driver BK At Driver Seat N/S
Power Seat Switch-Passenger BK At Passenger Seat N/S
Power Steering Pressure Switch BK Near Power Steering Pump 7
Power Window Circuit Breaker Under Instrument Panel 31, 35, 38
Power Window Motor-Driver BK In Driver Door at Motor 41
Power Window Motor-Left Rear BK In Door at Motor 43
Power Window Motor-Passenger BK In Passenger Door at Motor 42
Power Window Motor-Right Rear BK In Door at Motor 43
Power Window Switch-Left Rear BL In Door 43
Power Window Switch-Passenger Passenger Door 42
Power Window Switch-Right Rear BL In Door 43
Powertrain Control Module C1 BK Right Rear Engine Compartment 4, 8
Powertrain Control Module C2 WT Right Rear Engine Compartment 4, 8
Powertrain Control Module C3 GY Right Rear Engine Compartment 21
Powertrain Control Module C4 GN Right Rear Engine Compartment 4, 8
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(11) Remove the shift cable from the column shift
lever actuator (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT
CABLE - REMOVAL). (Fig. 3).
(12) Release the shift cable from the column
bracket and remove it from the bracket.
(13) Remove the SKIM module in order to discon-
nect the electrical connector.
(14) Remove the upper steering shaft coupler bolt
and slide the shaft down (Fig. 4) & (Fig. 5)(15) Remove the brake light switch and discard
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(16) Remove the four steering column mounting
nuts (Fig. 6).
Fig. 3 SHIFT CABLE CONNECTOR
1 - Shift lever
2 - Cable Connection
3 - Overdrive Electrical Wiring
4 - Mounting Screws
Fig. 4 COUPLER SHAFT
1 - MOUNTING HOLES
2 - COUPLER BOLT HOLE
Fig. 5 UPPER STEERING COUPLER
1 - STEERING COUPLER
2 - PINCH BOLT HOLE
Fig. 6 MOUNTING HOLES
1 - MOUNTING HOLES
19 - 8 COLUMNDR
COLUMN (Continued)

KEY CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal.
(1) Disconnect negative cable from battery.
(2) Remove upper and lower covers (shrouds) from
steering column.
(3) Place shifter in PARK position.
(4) A retaining pin (Fig. 12) is located at side of
key cylinder assembly.
(a) Rotate key to RUN position.
(b) Press in on retaining pin while pulling key
cylinder from ignition switch (Fig. 13).
INSTALLATION
The ignition key must be in the key cylinder for
cylinder installation.
(1) Install the key cylinder into the housing using
care to align the end of the key cylinder with the
ignition switch.
(2) Push the key cylinder in until it clicks.
(3) Replace the upper and lower shrouds.
(4) Reconnect the battery.
GEAR SHIFT LEVER
REMOVAL
(1) Remove the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER -
REMOVAL).
(2) Remove the upper and lower column shroud.
(3) Remove and discard the brake light switch.
(4) Loosen the column bolts and lower the column
enough to allow clearance for the gear shift lever
removal.
(5) Disconnect the overdrive switch harness (if
equipped).
(6) Disconnect the shift cable from the shift lever.
(7) Remove the SKIM.
(8) Remove the gear shift lever mounting screws
and remove the lever. (Fig. 14)
(9) Remove the blocker pin from the inhibit link
slot (Fig. 14).
INSTALLATION
(1) Install the lever assembly using care to install
the pin in the blocker to slider slot (Fig. 15) and
install the mounting screws and tighten to 12 N´m
(105 in. lbs.).
Fig. 12 KEY CYLINDER
1 - KEY
2 - KEY CYLINDER
3 - RETAINING PIN HOLE
Fig. 13 KEY CYLINDER
1 - KEY CYLINDER
2 - PUNCH
Fig. 14 GEAR SHIFT LEVER
1 - PARK INHIBIT BLOCKER SPRING
2 - GEAR SHIFT LEVER
19 - 12 COLUMNDR

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500..........1
MANUAL TRANSMISSION - NV4500..........43
MANUAL TRANSMISSION - NV5600..........88
AUTOMATIC TRANSMISSION - 48RE........130
AUTOMATIC TRANSMISSION - 45RFE/545RFE.311
TRANSFER CASE - NV241 GENII...........415TRANSFER CASE - NV271................447
TRANSFER CASE - NV243................482
TRANSFER CASE - NV244 GENII...........512
TRANSFER CASE - NV273................542
MANUAL TRANSMISSION - NV3500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING................3
REMOVAL.............................3
DISASSEMBLY..........................4CLEANING............................15
INSPECTION..........................16
ASSEMBLY............................17
INSTALLATION.........................39
SPECIFICATIONS.......................40
SPECIAL TOOLS.......................40
MANUAL TRANSMISSION -
NV3500
DESCRIPTION
The transmission is a medium-duty 5-speed, con-
stant mesh fully synchronized manual transmission
with fifth gear overdrive range. The transmission is
available in two and four-wheel drive configurations.
The transmission gear case consists of two aluminum
housings (Fig. 1). The clutch housing is an integral
part of the transmission front housing.
A combination of roller and ball bearings are used
to support the transmission shafts in the two hous-
ings. The transmission gears all rotate on caged type
needle bearings. A roller bearing is used between the
input and output shaft.
The transmission has a single shaft shift mecha-
nism with three shift forks all mounted on the shaft.
The shaft is supported in the front and rear housings
by bushings and one linear ball bearing. Internal
shift components consist of the forks, shaft, shift
lever socket and detent components
OPERATION
The manual transmission receives power through the
clutch assembly from the engine. The clutch disc issplined to the transmission input shaft and is turned at
engine speed at all times that the clutch is engaged.
The input shaft is connected to the transmission coun-
tershaft through the mesh of fourth speed gear on the
input shaft and the fourth countershaft gear. At this
point, all the transmission gears are spinning.
The driver selects a particular gear by moving the
shift lever to the desired gear position. This movement
moves the internal transmission shift components to
begin the shift sequence. As the shift lever moves the
selected shift rail, the shift fork attached to that rail
begins to move. The fork is positioned in a groove in the
outer circumference of the synchronizer sleeve. As the
shift fork moves the synchronizer sleeve, the synchro-
nizer begins to speed-up or slow down the selected gear
(depending on whether we are up-shifting or down-shift-
ing). The synchronizer does this by having the synchro-
nizer hub splined to the mainshaft and moving the
blocker ring into contact with the gear's friction cone. As
the blocker ring and friction cone come together, the
gear speed is brought up or down to the speed of the
synchronizer. As the two speeds match, the splines on
the inside of the synchronizer sleeve become aligned
with the teeth on the blocker ring and the friction cone
and eventually will slide over the teeth, locking the gear
to the mainshaft, or countershaft, through the synchro-
nizer.
DRTRANSMISSION AND TRANSFER CASE 21 - 1

MANUAL TRANSMISSION - NV4500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV4500
DESCRIPTION.........................43
OPERATION...........................43
DIAGNOSIS AND TESTING................44
REMOVAL.............................44
DISASSEMBLY.........................46
CLEANING............................62
INSPECTION..........................62
ASSEMBLY............................63
INSTALLATION.........................80
SPECIFICATIONS.......................81
SPECIAL TOOLS.......................81ADAPTER HOUSING SEAL
REMOVAL.............................85
INSTALLATION.........................85
EXTENSION HOUSING SEAL
REMOVAL.............................85
INSTALLATION.........................85
SHIFT MECHANISM
REMOVAL.............................86
INSTALLATION.........................87
SHIFT COVER
REMOVAL.............................87
INSTALLATION.........................87
MANUAL TRANSMISSION -
NV4500
DESCRIPTION
The NV4500 is a five speed constant mesh manual
transmission. All gear ranges including reverse are
synchronized. Fifth gear is an overdrive range. The
transmission has a cast iron gear case and aluminum
shift cover.
Two versions are used, a standard duty for 5.7L
applications and a heavy duty for V10 and Cummins
diesel applications. Main difference is a larger diam-
eter input shaft, for the heavy duty model.
Tapered roller bearings support the drive gear,
mainshaft and countershaft in the gear case. Roller
bearings in the drive gear support the forward end of
the mainshaft. The mainshaft gears are all supported
on caged type roller bearings. Drive gear thrust reac-
tion is controlled by a needle type thrust bearing.
The bearing is located at the forward end of the
mainshaft.
The transmission is a top loader style. The shift
lever is located in a shifter tower which is bolted to
the shift cover and operates the shift forks and rails
directly. The shift forks and rails are all located
within the aluminum cover which is bolted to the top
of the gear case.
IDENTIFICATION
The transmission identification tag is attached to
the driver side PTO cover (Fig. 1).
The tag provides the transmission model number,
build date and part number. Be sure to reinstall the
I.D. tag if removed during service. The information
on the tag is essential to correct parts ordering.
OPERATION
The manual transmission receives power through
the clutch assembly from the engine. The clutch disc
is splined to the transmission input shaft and is
turned at engine speed at all times that the clutch is
engaged. The input shaft is connected to the trans-
mission countershaft through the mesh of fourth
speed gear on the input shaft and the fourth counter-
shaft gear. At this point all the transmission gears
are spinning.
Fig. 1 IDENTIFICATION TAG LOCATION
1 - PTO COVER
2 - I.D. TAG
DRMANUAL TRANSMISSION - NV4500 21 - 43

MANUAL TRANSMISSION - NV5600
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV5600
DESCRIPTION.........................88
OPERATION...........................90
DIAGNOSIS AND TESTING................90
REMOVAL.............................90
DISASSEMBLY.........................91
CLEANING - TRANSMISSION.............106
INSPECTION.........................106
ASSEMBLY...........................106
INSTALLATION........................121
SPECIFICATIONS - NV5600..............123SPECIAL TOOLS.......................123
ADAPTER HOUSING SEAL
REMOVAL............................128
INSTALLATION........................128
EXTENSION HOUSING SEAL
REMOVAL............................128
INSTALLATION........................128
SHIFT COVER
REMOVAL............................129
INSTALLATION........................129
MANUAL TRANSMISSION -
NV5600
DESCRIPTION
The NV5600 is a six speed constant mesh manual
transmission (Fig. 1). All gear ranges including
reverse are synchronized. First and second gears uti-
lize dual cone synchronizers in order to aid shifting.
Sixth gear is an overdrive range. The transmission
uses cast iron for the gear case and extension/
adapter housing and aluminum for the clutch hous-
ing.To drain the trans remove the bottom PTO cover
bolt. Fill the trans through the plug to the rear of the
PTO cover (Fig. 1). Dry fill is approximately 4.5 liters
(9.5 pints) or to the bottom edge of the fill plug hole.
The gear ratios are:GEAR RATIOS
GEAR RATIO
FIRST 5.63:1
SECOND 3.38:1
THIRD 2.04:1
FOURTH 1.39:1
FIFTH 1.00:1
SIXTH 0.73:1
REVERSE 5.63:1
21 - 88 MANUAL TRANSMISSION - NV5600DR

OUTPUT SHAFT FRONT BEARING
REMOVAL............................216
INSTALLATION........................216
OUTPUT SHAFT REAR BEARING
REMOVAL............................216
INSTALLATION........................217
OVERDRIVE CLUTCH
DESCRIPTION........................217
OPERATION..........................217
OVERDRIVE UNIT
REMOVAL............................218
DISASSEMBLY........................218
CLEANING...........................225
INSPECTION.........................225
ASSEMBLY...........................226
INSTALLATION........................235
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION........................236
OPERATION..........................236
DISASSEMBLY........................236
CLEANING...........................236
INSPECTION.........................237
ASSEMBLY...........................237
PISTONS
DESCRIPTION........................239
OPERATION..........................239
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION........................241
OPERATION..........................241
DISASSEMBLY........................242
INSPECTION.........................243
ASSEMBLY...........................244
REAR CLUTCH
DESCRIPTION........................247
OPERATION..........................248
DISASSEMBLY........................248
CLEANING...........................248
INSPECTION.........................248
ASSEMBLY...........................249
REAR SERVO
DESCRIPTION........................251
OPERATION..........................251
DISASSEMBLY........................251
CLEANING...........................251
ASSEMBLY...........................251
SHIFT MECHANISM
DESCRIPTION........................252OPERATION..........................252
SOLENOID
DESCRIPTION........................252
OPERATION..........................252
SPEED SENSOR
DESCRIPTION........................253
OPERATION..........................253
THROTTLE VALVE CABLE
DESCRIPTION........................253
ADJUSTMENTS - THROTTLE VALVE CABLE . 254
TORQUE CONVERTER
DESCRIPTION........................255
OPERATION..........................259
REMOVAL............................260
INSTALLATION........................260
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION........................261
OPERATION..........................261
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE........261
TOW/HAUL OVERDRIVE SWITCH
DESCRIPTION........................261
OPERATION..........................262
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS..............262
REMOVAL............................262
INSTALLATION........................262
TRANSMISSION RANGE SENSOR
DESCRIPTION........................263
OPERATION..........................263
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS)................264
REMOVAL............................265
INSTALLATION........................266
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION........................267
OPERATION..........................267
VALVE BODY
DESCRIPTION........................267
OPERATION..........................272
REMOVAL............................286
DISASSEMBLY........................287
CLEANING...........................298
INSPECTION.........................298
ASSEMBLY...........................299
INSTALLATION........................309
ADJUSTMENTS - VALVE BODY...........310
DRAUTOMATIC TRANSMISSION - 48RE 21 - 131

AUTOMATIC TRANSMISSION -
48RE
DESCRIPTION
The 48RE (Fig. 1) is a four speed fully automatic
transmissions with an electronic governor. The 48RE
is equipped with a lock-up clutch in the torque con-
verter. First through third gear ranges are provided
by the clutches, bands, overrunning clutch, and plan-
etary gear sets in the transmission. Fourth gear
range is provided by the overdrive unit that contains
an overdrive clutch, direct clutch, planetary gear set,
and overrunning clutch.
The transmission contains a front, rear, and direct
clutch which function as the input driving compo-
nents. It also contains the kickdown (front) and thelow/reverse (rear) bands which, along with the over-
running clutch and overdrive clutch, serve as the
holding components. The driving and holding compo-
nents combine to select the necessary planetary gear
components, in the front, rear, or overdrive planetary
gear set, transfer the engine power from the input
shaft through to the output shaft.
The valve body is mounted to the lower side of the
transmission and contains the valves to control pres-
sure regulation, fluid flow control, and clutch/band
application. The oil pump is mounted at the front of
the transmission and is driven by the torque con-
verter hub. The pump supplies the oil pressure nec-
essary for clutch/band actuation and transmission
lubrication.
21 - 132 AUTOMATIC TRANSMISSION - 48REDR

IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas-
ket surface (Fig. 2). Refer to this information when
ordering replacement parts.
GEAR RATIOS
The 48RE gear ratios are:
1st.................................2.45:1
2nd................................1.45:1
3rd................................1.00:1
4th.................................0.69:1
Rev.................................2.20:1
OPERATION
The application of each driving or holding compo-
nent is controlled by the valve body based upon the
manual lever position, throttle pressure, and gover-
nor pressure. The governor pressure is a variable
pressure input to the valve body and is one of the
signals that a shift is necessary. First through fourth
gear are obtained by selectively applying and releas-
ing the different clutches and bands. Engine power is
thereby routed to the various planetary gear assem-
blies which combine with the overrunning clutch
assemblies to generate the different gear ratios. The
torque converter clutch is hydraulically applied and
is released when fluid is vented from the hydraulic
circuit by the torque converter control (TCC) solenoid
on the valve body. The torque converter clutch is con-
trolled by the Powertrain Control Module (PCM). The
torque converter clutch engages in fourth gear, and
in third gear under various conditions, such as when
the O/D switch is OFF, when the vehicle is cruising
on a level surface after the vehicle has warmed up.
The torque converter clutch can also be engaged in
the MANUAL SECOND gear position if high trans-
mission temperatures are sensed by the PCM. The
torque converter clutch will 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 pressure is increased. The torque con-
verter clutch feature increases fuel economy and
reduces the transmission fluid temperature.
Since the overdrive clutch is applied in fourth gear
only and the direct clutch is applied in all ranges
except fourth gear, the transmission operation for
park, neutral, and first through third gear will be
described first. Once these powerflows are described,
the third to fourth shift sequence will be described.
1 - TORQUE CONVERTER 10 - OVERDRIVE CLUTCH
2 - INPUT SHAFT 11 - DIRECT CLUTCH
3 - OIL PUMP 12 - PLANETARY GEAR
4 - FRONT BAND 13 - INTERMEDIATE SHAFT
5 - FRONT CLUTCH 14 - OVERDRIVE OVERRUNNING CLUTCH
6 - REAR CLUTCH 15 - DIRECT CLUTCH SPRING
7 - PLANETARIES 16 - OVERDRIVE PISTON RETAINER
8 - REAR BAND 17 - OIL PAN
9 - OVERRUNNING CLUTCH 18 - VALVE BODY
Fig. 2 Transmission Part Number And Serial
Number Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
21 - 134 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)