DODGE RAM 1500 1998 2.G Workshop Manual

is applied. The clutch application can also be felt by
touching the appropriate element while applying air
pressure. As the air pressure is released, the clutch
should also release.
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK
When diagnosing converter housing fluid leaks,
two items must be established before repair.
(1) Verify that a leak condition actually exists.
(2) Determined the true source of the leak.
Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill or fill after repair.
Converter housing leaks have several potential
sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair. Torque converter seal leaks tend to move
along the drive hub and onto the rear of the con-
verter. Pump cover seal tend to run down the cover
and the inside surface of the bellhousing.
Some leaks, or suspected leaks, may be particu-
larly difficult to locate. If necessary, a Mopart
approved dye may be used to locate a leak.
TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
(1) Leaks at the weld joint around the outside
diameter weld (Fig. 7).
(2) Leaks at the converter hub weld (Fig. 7).
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle
(3) Remove any necessary skid plates. (Refer to 13
- FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(4) Mark propeller shaft and axle companion
flanges for assembly alignment.
(5) Remove the rear propeller shaft
(6) Remove the front propeller shaft, if necessary.
(7) Remove the engine to transmission collar (Fig.
8).
(8) Remove the exhaust support bracket from the
rear of the transmission.
(9) Disconnect and lower or remove any necessary
exhaust components.
Fig. 7 Torque Converter Assembly
1 - TURBINE ASSEMBLY
2-STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - STRUCTURAL DUST COVER
3 - TRANSMISSION
21 - 318 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(10) Remove the starter motor.
(11) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(12) Disengage the output speed sensor connector
from the output speed sensor (Fig. 9).
(13) Disengage the input speed sensor connector
from the input speed sensor (Fig. 10).(14) Disengage the transmission solenoid/TRS
assembly connector from the transmission solenoid/
TRS assembly (Fig. 11).
(15) Disengage the line pressure sensor connector
from the line pressure sensor (Fig. 12).
Fig. 9 Disconnect Output Speed Sensor
1 - TRANSMISSION
2 - OUTPUT SPEED SENSOR
Fig. 10 Disconnect Input Speed Sensor
1 - TRANSMISSION
2 - INPUT SPEED SENSOR
Fig. 11 Disconnect Transmission Solenoid/TRS
Assembly
1 - TRANSMISSION
2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
Fig. 12 Disconnect Line Pressure Sensor
1 - TRANSMISSION
2 - LINE PRESSURE SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 319
AUTOMATIC TRANSMISSION - 45RFE/545RFE (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
21 - 320 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(6) Inspect the ends of the sensors for debris,
which may indicate the nature of the transmission
failure.
(7) Install Support Stand 8257 onto the transmis-
sion case (Fig. 16).
(8) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 17).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.
(9) Remove the bolts holding the transmission
extension/adapter housing to the transmission case.
(10) Remove the extension/adapter housing from
the transmission case.
(11) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator
C-3339, measure and record the output shaft end-
play (Fig. 18).
Fig. 16 Install Support Stand - Tool 8257
1 - TOOL 8257
Fig. 17 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 18 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 321
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(12) Remove the bolts holding the transmission oil
pan to the transmission case.
(13) Remove the transmission oil pan from the
transmission case.
(14) Remove the primary oil filter and the oil
cooler return filter (Fig. 19).
(15) Remove the cooler return filter bypass valve.
(16) Remove the bolts holding the valve body to
the transmission case (Fig. 20).
(17) Remove the valve body from the transmission
case.(18) Remove the outer snap-ring securing the
transmission front cover into the transmission case
(Fig. 21).
(19) Remove the inner snap-ring securing the
transmission front cover to the oil pump (Fig. 21).
Fig. 19 Remove Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 20 Remove Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
Fig. 21 Remove Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
21 - 322 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(20) Reaching through a case opening in the valve
body area with a long blunted tool, remove the trans-
mission front cover from the transmission case.
(21) Remove the bolts holding the oil pump into
the transmission case (Fig. 22).
(22) Remove the oil pump. Hold inward on the
input shaft to prevent pulling the input clutch
assembly with the oil pump (Fig. 22).
NOTE: If the input shaft is not held during oil pump
removal, the input clutch assembly will attempt to
move forward with the oil pump and the numbers 2,
3, or 4 bearings inside the input clutch assembly
may become dislodged.
(23) Remove the number 1 bearing from the input
clutch assembly (Fig. 23).
(24) Remove the input clutch assembly from the
transmission case (Fig. 23).
(25) Remove the number 5 bearing and selective
thrust plate from the input clutch assembly (Fig. 23),
or the 4C clutch retainer/bulkhead.
(26) Remove the 4C clutch retainer/bulkhead
tapered snap-ring from the transmission case (Fig.
24).
(27) Remove the 4C clutch retainer/bulkhead from
the transmission case (Fig. 24).
Fig. 22 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 23 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 24 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 323
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(28) Remove the front 2C clutch pack snap-ring
from the transmission case (Fig. 25).
(29) Remove the 2C clutch pack from the transmis-
sion case (Fig. 25).
(30) Remove the rear selective plate and number 6
bearing from the reaction annulus (Fig. 26).
(31) Remove the reaction annulus from the reac-
tion planetary carrier (Fig. 26).
(32) Remove the number 7 bearing (Fig. 26).
(33) Remove the reaction sun gear (Fig. 26).
(34) Remove the number 8 bearing from the reac-
tion planetary carrier (Fig. 26).
(35) Remove the reaction planetary carrier (Fig.
26). Note that this planetary gear set has three pin-
ion gears.
(36) Remove the number 9 bearing from the
reverse planetary gear set (Fig. 26).
Fig. 25 Remove 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 26 Remove Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
21 - 324 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(37) Remove the snap-ring holding the park sprag
gear onto the output shaft (Fig. 27).
(38) Remove the park sprag gear from the output
shaft (Fig. 28).(39) Remove the input/reverse planetary assembly
(Fig. 29).
(40) Remove the number 12 bearing from the
input/reverse planetary assembly (Fig. 29).
(41) Remove the snap-ring holding the low/reverse
clutch retainer into the transmission case (Fig. 30).
(42) Remove the low/reverse clutch retainer from
the transmission case (Fig. 30).
Fig. 27 Remove Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 28 Remove Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 29 Remove Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
Fig. 30 Remove Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 325
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(43) Remove the park pawl rod and e-clip (Fig. 31).
(44) Remove the park pawl rod guide snap-ring
(Fig. 31).
(45) Remove the park pawl rod guide (Fig. 31).
(46) Remove the park pawl pivot shaft, park pawl,
and spring (Fig. 31).
(47) Remove the manual selector shaft (Fig. 31).
(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
CLEANING
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on shafts,
or valves, use extreme care to avoid rounding off sharp
edges. Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or O-rings
during overhaul. Replace these parts as a matter of
course. Also do not reuse snap rings or E-clips that are
bent or distorted. Replace these parts as well.
Lubricate transmission parts with MopartATF +4,
Automatic Transmission Fluid, during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-Glyde to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the cooler filter bypass valve.
(3) Torque the bypass valve to specification. The
valve uses a tapered pipe thread and excessive
torque can damage the transmission case. Tighten
the cooler filter bypass valve to 4.5 N´m (40 in.lbs.).
(4) Install a new selector shaft seal using Seal
Installer 8253 (Fig. 32).
Fig. 31 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 32 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
21 - 326 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(5) Install the manual selector shaft and retaining
screw. Tighten the manual selector shaft retaining
screw to 28 N´m (250 in.lbs.).
(6) Install the park pawl, spring, and shaft (Fig.
33).
(7) Install the park rod and e-clip (Fig. 33).
(8) Install the park rod guide and snap-ring (Fig.
33).
(9) Install a new dipstick tube seal using Seal
Installer 8254 (Fig. 34).
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).
(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
Fig. 33 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 34 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 35 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 327
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)