Starter solenoid DODGE RAM 1500 1998 2.G Owner's Manual

STANDARD PROCEDURE
STANDARD PROCEDURES - WATER DRAINING
AT FUEL FILTER
Refer to Fuel Filter/Water Separator removal/in-
stallation for procedures.
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM PARTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
STANDARD PROCEDURE - FUEL SYSTEM
PRIMING
A certain amount of air becomes trapped in the
fuel system when fuel system components on the
supply and/or high-pressure side are serviced or
replaced. Fuel system priming is accomplished using
the electric fuel transfer (lift) pump.
Servicing or replacing fuel system components will
not require fuel system priming.
The fuel transfer (lift) pump is self-priming: When
the key is first turned on (without cranking engine),
the pump operates for approximately 1 to 2 second
and then shuts off. The pump will also operate for up
to 25 seconds after the starter is quickly engaged,
and then disengaged without allowing the engine to
start. The pump shuts off immediately if the key is
on and the engine stops running.
(1) Turn key to CRANK position and quickly
release key to ON position before engine starts. This
will operate fuel transfer pump for approximately 25
seconds.
(2) Crank engine. If the engine does not start after
25 seconds, turn key OFF. Repeat previous step until
engine starts.
(3) Fuel system priming is now completed.
(4) Attempt to start engine. If engine will not
start, proceed to following steps.When engine does
start, it may run erratically and be noisy for a
few minutes. This is a normal condition.
CAUTION: Do not engage the starter motor for more
than 30 seconds at a time. Allow two minutes
between cranking intervals.
(5) Perform previous fuel priming procedure steps
using fuel transfer pump. Be sure fuel is present at
fuel tank.
(6) Crank the engine for 30 seconds at a time to
allow fuel system to prime.
WARNING: THE FUEL INJECTION PUMP SUPPLIES
EXTREMELY HIGH FUEL PRESSURE TO EACH INDI-
VIDUAL INJECTOR THROUGH THE HIGH-PRES-
SURE LINES. FUEL UNDER THIS AMOUNT OF
PRESSURE CAN PENETRATE THE SKIN AND
CAUSE PERSONAL INJURY. WEAR SAFETY GOG-
GLES AND ADEQUATE PROTECTIVE CLOTHING.
DO NOT LOOSEN FUEL FITTINGS WHILE ENGINE
IS RUNNING.
WARNING: ENGINE MAY START WHILE CRANKING
STARTER MOTOR.
Fig. 2 FUEL INJECTORS
1 - SOLENOID CONNECTIONS
2 - ROCKER HOUSING
3 - FUEL INJECTOR
4 - PASSTHROUGH CONNECTOR
DRFUEL DELIVERY - DIESEL 14 - 47
FUEL DELIVERY - DIESEL (Continued)

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
NOTE: The overdrive unit can be removed and ser-
viced separately. It is not necessary to remove the
entire transmission assembly to perform overdrive
unit repairs.
(1) Disconnect battery negative cable.
(2) Raise vehicle.
(3) Remove the transfer case skid plate (Fig. 12), if
equipped.(4) Disconnect and lower or remove necessary
exhaust components.
(5) Remove engine-to-transmission struts.
(6) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(7) Disconnect and remove the crankshaft position
sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain the sensor attaching bolts.
(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove torque converter access cover.
(10) 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.
(11) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(12) Disconnect wires from the transmission range
sensor and transmission solenoid connector.
(13) Disconnect gearshift cable (Fig. 13) from the
transmission.
Fig. 12 Transfer Case Skid Plate
1 - FRAME RAIL
2 - SKID PLATE
3 - BOLTS (6)
Fig. 13 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
21 - 158 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

(13) Install bolts attaching converter housing to
engine.
(14) Install rear support.
(15) Install the rear transmission crossmember.
(16) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member.
(17) Remove engine support fixture.
(18) Install the transfer case, if equipped.
(19) Install crankshaft position sensor. (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT
POSITION SENSOR - INSTALLATION)
(20) Connect gearshift cable (Fig. 64) and throttle
cable to transmission.
(21) Connect wires to the transmission range sen-
sor and transmission solenoid connector. Be sure the
transmission harnesses are properly routed.
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.
(23) Install converter housing access cover.
(24) Install starter motor and cooler line bracket.
(Refer to 8 - ELECTRICAL/STARTING/STARTER
MOTOR - INSTALLATION)
(25) Connect cooler lines (Fig. 65) to transmission.
(26) Install transmission fill tube. Install new seal
on tube before installation.
(27) Install any exhaust components previously
removed.
(28) Align and connect propeller shaft. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(29) Adjust gearshift cable and throttle valve
cable, if necessary.
(30) Install the transfer case skid plate, if
equipped.
(31) Lower vehicle.
(32) Fill transmission with MopartATF +4, Auto-
matic Transmission fluid.
Fig. 64 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
Fig. 65 Transmission Cooler Lines
1 - TRANSMISSION
2 - RADIATOR
3 - COOLER LINES
DRAUTOMATIC TRANSMISSION - 48RE 21 - 175
AUTOMATIC TRANSMISSION - 48RE (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)

(9) Fill the transmission with the recommended
fluid.
TRANSMISSION CONTROL
RELAY
DESCRIPTION
The relay is supplied fused B+ voltage, energized
by the TCM, and is used to supply power to the sole-
noid pack when the transmission is in normal oper-
ating mode.
OPERATION
When the relay is ªoffº, no power is supplied to the
solenoid pack and the transmission is in ªlimp-inº
mode. After a controller reset, the TCM energizes the
relay. Prior to this, the TCM verifies that the con-
tacts are open by checking for no voltage at the
switched battery terminals. After this is verified, the
voltage at the solenoid pack pressure switches is
checked. After the relay is energized, the TCM mon-
itors the terminals to verify that the voltage is
greater than 3 volts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmission Range Sensor (TRS) is part of
the solenoid module, which is mounted to the top of
the valve body inside the transmission.
The Transmission Range Sensor (TRS) has five
switch contact pins that:
²Determine shift lever position
²Supply ground to the Starter Relay in Park and
Neutral only.
²
Supply +12 V to the backup lamps in Reverse only.
The TRS also has an integrated temperature sen-
sor (thermistor) that communicates transmission
temperature to the TCM and PCM.
OPERATION
The Transmission Range Sensor (TRS) communi-
cates shift lever position to the TCM as a combina-
tion of open and closed switches. Each shift lever
position has an assigned combination of switch states
(open/closed) that the TCM receives from four sense
circuits. The TCM interprets this information and
determines the appropriate transmission gear posi-
tion and shift schedule.
There are many possible combinations of open and
closed switches (codes). Seven of these possible codes
are related to gear position and five are recognized
as ªbetween gearº codes. This results in many codes
which shouldnever occur. These are called
ªinvalidº codes. An invalid code will result in a DTC,
and the TCM will then determine the shift lever
position based on pressure switch data. This allows
reasonably normal transmission operation with a
TRS failure.
GEAR C5 C4 C3 C2 C1
ParkCL OP OP CL CL
Temp 1CL OP OP CL OP
ReverseOP OP OP CL OP
Temp 2OP OP CL CL OP
Neutral 1OP OP CL CL CL
Neutral 2OP CL CL CL CL
Temp 3OP CL CL CL OP
DriveOP CL CL OP OP
Temp 4OP CL OP OP OP
Manual 2CL CL OP OP OP
Temp 5CL OP OP OP OP
Manual 1CL OP CL OP OP
Fig. 125 Checking Torque Converter Seating-Typical
1 - SCALE
2 - STRAIGHTEDGE
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 405
TORQUE CONVERTER (Continued)

SOLENOID - DESCRIPTION, EVAP/PURGE . 25-12
SOLENOID - INSTALLATION, EVAP/
PURGE.............................25-12
SOLENOID - OPERATION..............21-252
SOLENOID - OPERATION, EVAP/PURGE . . . 25-12
SOLENOID - REMOVAL, EVAP/PURGE.....25-12
SOLENOID SWITCH VALVE -
DESCRIPTION......................21-398
SOLENOID SWITCH VALVE - OPERATION . 21-398
SOLENOIDS - DESCRIPTION...........21-398
SOLENOIDS - OPERATION.............21-399
SOLENOID/TRS ASSEMBLY -
DESCRIPTION, TRANSMISSION........21-406
SOLENOID/TRS ASSEMBLY -
INSTALLATION, TRANSMISSION........21-408
SOLENOID/TRS ASSEMBLY -
OPERATION, TRANSMISSION..........21-406
SOLENOID/TRS ASSEMBLY - REMOVAL,
TRANSMISSION.....................21-407
SOLID LIFTERS/TAPPETS - CLEANING....9-279
SOLID LIFTERS/TAPPETS - INSPECTION . . 9-279
SOLID LIFTERS/TAPPETS -
INSTALLATION.......................9-280
SOLID LIFTERS/TAPPETS - REMOVAL....9-279
SPARE / TEMPORARY TIRE -
DESCRIPTION.......................22-15
SPARE TIRE / TEMPORARY -
DESCRIPTION........................22-6
SPARE WHEEL WITH MATCHING TIRE -
DESCRIPTION, FULL SIZE..............22-15
SPARK PLUG - DESCRIPTION...........8I-17
SPARK PLUG - REMOVAL..............8I-19
SPARK PLUG CABLE - DESCRIPTION.....8I-21
SPARK PLUG CABLE - INSTALLATION.....8I-22
SPARK PLUG CABLE - OPERATION.......8I-21
SPARK PLUG CABLE - REMOVAL........8I-22
SPARK PLUG CABLE RESISTANCE,
SPECIFICATIONS......................8I-4
SPARK PLUG CONDITIONS - DIAGNOSIS
AND TESTING........................8I-17
SPARK PLUGS, SPECIFICATIONS..........8I-4
SPEAKER - DESCRIPTION..............8A-13
SPEAKER - DIAGNOSIS AND TESTING....8A-13
SPEAKER - INSTALLATION.............8A-15
SPEAKER - OPERATION...............8A-13
SPEAKER - REMOVAL.................8A-14
SPECIFICATIONS......................7-20
SPEED CONTROL - DESCRIPTION........8P-1
SPEED CONTROL - OPERATION..........8P-2
SPEED CONTROL - TORQUE.............8P-3
SPEED SENSOR - DESCRIPTION........21-253
SPEED SENSOR - DESCRIPTION, FRONT
WHEEL.............................5-47
SPEED SENSOR - DESCRIPTION, INPUT . 21-382
SPEED SENSOR - DESCRIPTION,
OUTPUT...........................21-391
SPEED SENSOR - DIAGNOSIS AND
TESTING, REAR WHEEL................5-49
SPEED SENSOR - INSTALLATION, FRONT
WHEEL.............................5-48
SPEED SENSOR - INSTALLATION, INPUT . 21-382
SPEED SENSOR - INSTALLATION,
OUTPUT...........................21-392
SPEED SENSOR - INSTALLATION, REAR
WHEEL.............................5-48
SPEED SENSOR - OPERATION.........21-253
SPEED SENSOR - OPERATION, FRONT
WHEEL.............................5-47
SPEED SENSOR - OPERATION, INPUT . . . 21-382
SPEED SENSOR - OPERATION, OUTPUT . . 21-391
SPEED SENSOR - REMOVAL, FRONT
WHEEL.............................5-48
SPEED SENSOR - REMOVAL, INPUT.....21-382
SPEED SENSOR - REMOVAL, OUTPUT . . . 21-391
SPEED SENSOR - REMOVAL, REAR
WHEEL.............................5-48
SPEEDOMETER - DESCRIPTION.........8J-37
SPEEDOMETER - OPERATION...........8J-37
SPEEDS - DESCRIPTION, TIRE
PRESSURE FOR HIGH
..................22-7
SPLASH SHIELD - INSTALLATION,
FRONT WHEELHOUSE
.................23-41
SPLASH SHIELD - INSTALLATION, REAR
WHEELHOUSE
.......................23-41
SPLASH SHIELD - REMOVAL, FRONT
WHEELHOUSE
.......................23-41
SPLASH SHIELD - REMOVAL, REAR
WHEELHOUSE
.......................23-41SPLICE INFORMATION - DESCRIPTION,
CONNECTOR, GROUND..............8W-01-7
SPLICING - STANDARD PROCEDURE,
WIRE...........................8W-01-15
SPRING - DESCRIPTION................2-44
SPRING - INSTALLATION.......2-23,2-39,2-44
SPRING - OPERATION..................2-44
SPRING - REMOVAL...........2-22,2-39,2-44
SPRING AND SHOCK - DIAGNOSIS AND
TESTING............................2-41
SPRING BUMPERS (3500) -
INSTALLATION, AUXILIARY..............2-43
SPRING BUMPERS (3500) - REMOVAL,
AUXILIARY..........................2-43
SPRING TIP INSERTS - INSTALLATION....2-45
SPRING TIP INSERTS - REMOVAL........2-44
SPRINGS - DESCRIPTION, VALVE . . . 9-126,9-32,
9-38
SPRINGS - INSTALLATION, VALVE . . 9-127,9-204,
9-32,9-38
SPRINGS - REMOVAL, VALVE . 9-126,9-204,9-32,
9-38
SPRINGS - STANDARD PROCEDURE,
VALVES, GUIDES.....................9-256
SPRINGS AND SEALS - REMOVAL,
VALVE .............................9-260
SPROCKETS - INSPECTION, TIMING
BELT/CHAIN.....................9-174,9-84
SPROCKETS - INSTALLATION, TIMING
BELT/CHAIN.....................9-176,9-85
SPROCKETS - INSTALLATION,
TIMING/CHAIN........................9-228
SPROCKETS - REMOVAL, TIMING
BELT/CHAIN.....................9-172,9-83
SPROCKETS - REMOVAL, TIMING/CHAIN . . 9-228
SQUEAK & RATTLE - STANDARD
PROCEDURE, BUZZ...................23-11
STABILIZER BAR - DESCRIPTION.........2-24
STABILIZER BAR - INSTALLATION....2-25,2-40
STABILIZER BAR - OPERATION...........2-25
STABILIZER BAR - REMOVAL........2-25,2-39
STAKING - STANDARD PROCEDURE,
HEAT ...............................23-3
STANDARD CAB - INSTALLATION . . 8O-35,8O-61
STANDARD CAB - REMOVAL......8O-32,8O-59
STARTER MOTOR - DIAGNOSIS AND
TESTING...........................8F-32
STARTER MOTOR - INSTALLATION.......8F-34
STARTER MOTOR - REMOVAL..........8F-33
STARTER MOTOR RELAY - DESCRIPTION . 8F-35
STARTER MOTOR RELAY -
INSTALLATION.......................8F-37
STARTER MOTOR RELAY - OPERATION . . . 8F-36
STARTER MOTOR RELAY - REMOVAL.....8F-37
STARTER RELAY - DIAGNOSIS AND
TESTING...........................8F-36
STARTING - DESCRIPTION.............8F-26
STARTING - OPERATION...............8F-26
STARTING - STANDARD PROCEDURE,
JUMP...............................0-19
STARTING SYSTEM - DIAGNOSIS AND
TESTING...........................8F-27
STARTING SYSTEM - SPECIFICATIONS,
TORQUE............................8F-32
STARTING SYSTEM, SPECIFICATIONS
.....8F-31
STATE DISPLAY TEST MODE -
DESCRIPTION
........................25-1
STEERING - DESCRIPTION
..............19-1
STEERING - OPERATION
................19-1
STEERING COLUMN - DIAGNOSIS AND
TESTING
............................19-7
STEERING COLUMN OPENING COVER -
INSTALLATION
.......................23-60
STEERING COLUMN OPENING COVER -
REMOVAL
..........................23-60
STEERING COLUMN OPENING SUPPORT
BRACKET - INSTALLATION
.............23-60
STEERING COLUMN OPENING SUPPORT
BRACKET - REMOVAL
.................23-60
STEERING COUPLING - INSTALLATION,
UPPER
.............................19-13
STEERING COUPLING - REMOVAL,
UPPER
.............................19-13
STEERING FLOW AND PRESSURE -
DIAGNOSIS AND TESTING, POWER
.......19-4
STEERING FLUID - DESCRIPTION,
POWER
..............................0-3STEERING FLUID LEVEL CHECKING -
STANDARD PROCEDURE, POWER.......19-43
STEERING GEAR INPUT SHAFT SEAL -
INSTALLATION.......................19-29
STEERING GEAR INPUT SHAFT SEAL -
REMOVAL..........................19-27
STEERING GEAR, SPECIAL TOOLS -
POWER............................19-23
STEERING GEAR, SPECIFICATIONS -
POWER............................19-22
STEERING LINKAGE, SPECIAL TOOLS....19-35
STEERING PRESSURE SWITCH -
DESCRIPTION, POWER................19-46
STEERING PRESSURE SWITCH -
OPERATION, POWER..................19-46
STEERING PUMP - INITIAL OPERATION -
STANDARD PROCEDURE, POWER.......19-40
STEERING, SPECIAL TOOLS.............19-5
STEERING SYSTEM - DIAGNOSIS AND
TESTING, POWER.....................19-2
STEERING SYSTEM - STANDARD
PROCEDURE, FLUSHING POWER........19-40
STEERING WHEEL - INSTALLATION......19-15
STEERING WHEEL - REMOVAL..........19-15
STEM SEALS - DESCRIPTION, VALVE....9-127,
9-203
STOP LAMP - INSTALLATION, CENTER
HIGH MOUNTED.....................8L-11
STOP LAMP - REMOVAL, CENTER HIGH
MOUNTED..........................8L-11
STOP LAMP UNIT - INSTALLATION,
CENTER HIGH MOUNTED..............8L-11
STOP LAMP UNIT - REMOVAL, CENTER
HIGH MOUNTED.....................8L-11
STORAGE BIN - INSTALLATION..........23-61
STORAGE BIN - INSTALLATION, UNDER
SEAT ..............................23-80
STORAGE BIN - REMOVAL.............23-61
STORAGE BIN - REMOVAL, UNDER SEAT . . 23-80
STORAGE BIN COVERING -
INSTALLATION, UNDER SEAT...........23-80
STORAGE BIN COVERING - REMOVAL,
UNDER SEAT........................23-80
STORAGE BIN LATCH - INSTALLATION,
UNDER SEAT........................23-80
STORAGE BIN LATCH - REMOVAL,
UNDER SEAT........................23-80
STORAGE BIN LID - INSTALLATION,
UNDER SEAT........................23-80
STORAGE BIN LID - REMOVAL, UNDER
SEAT ..............................23-80
STRAP - DESCRIPTION, RADIO NOISE
SUPPRESSION GROUND................8A-9
STRAP - INSTALLATION, RADIO NOISE
SUPPRESSION GROUND...............8A-10
STRAP - OPERATION, RADIO NOISE
SUPPRESSION GROUND................8A-9
STRAP - REMOVAL, RADIO NOISE
SUPPRESSION GROUND................8A-9
STRIKER - INSTALLATION, LATCH . . 23-17,23-23,
23-33
STRIKER - REMOVAL, LATCH . 23-16,23-23,23-33
STRIKER / SECONDARY CATCH -
INSTALLATION, LATCH................23-48
STRIKER / SECONDARY CATCH -
REMOVAL, LATCH....................23-47
STRUCTURAL ADHESIVE LOCATIONS -
SPECIFICATIONS....................23-112
STRUCTURAL COVER - DESCRIPTION....9-145,
9-216,9-57
STRUCTURAL COVER - INSTALLATION . . . 9-145,
9-216,9-57
STRUCTURAL COVER - OPERATION.....9-145,
9-216,9-57
STRUCTURAL COVER - REMOVAL . . 9-145,9-216,
9-57
STUDS - INSTALLATION...............22-14
STUDS - REMOVAL...................22-14
SUCTION LINE - DESCRIPTION..........24-70
SUN VISOR - INSTALLATION...........23-70
SUN VISOR - REMOVAL
...............23-70
SUN VISOR SUPPORT - INSTALLATION
. . . 23-71
SUN VISOR SUPPORT - REMOVAL
.......23-70
SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A
.........8O-7
SUPPLEMENTAL RESTRAINT SYSTEM -
DIAGNOSIS AND TESTING
..............8O-6
DRINDEX 31
Description Group-Page Description Group-Page Description Group-Page