Transmission install DODGE RAM 1500 1998 2.G Workshop Manual

INSTALLATION
(1) Route the transmission end of the gearshift
cable through the opening in the dash panel (Fig.
72).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column
bracket so the retaining ears (Fig. 73) are engaged
and snap the cable eyelet onto the shift lever ball
stud.(4) Raise the vehicle.
(5) Place the transmission manual shift lever in
the ªPARKº detent (rearmost) position and rotate
prop shaft to ensure transmission is in PARK.
(6) Route the gearshift cable through the transmis-
sion mounting bracket and secure the cable by snap-
ping the cable retaining ears into the transmission
bracket and snapping the cable eyelet on the manual
shift lever ball stud.
(7) Lower vehicle.
(8) Lock the shift cable adjustment by pressing the
cable adjuster lock tab downward until it snaps into
place.
(9) Check for proper operation of the transmission
range sensor.
(10) Adjust the gearshift cable (Refer to 21 -
TRANSMISSION/AUTOMATIC/GEAR SHIFT
CABLE - ADJUSTMENTS) and BTSI mechanism
(Refer to 21 - TRANSMISSION/AUTOMATIC/
BRAKE TRANSMISSION SHIFT INTERLOCK SYS-
TEM - ADJUSTMENTS) as necessary.
ADJUSTMENTS
GEARSHIFT CABLE
Check adjustment by starting the engine in PARK
and NEUTRAL. Adjustment is CORRECT if the
engine starts only in these positions. Adjustment is
INCORRECT if the engine starts in one but not both
positions. If the engine starts in any position other
than PARK or NEUTRAL, or if the engine will not
start at all, the transmission range sensor may be
faulty.
Gearshift Adjustment Procedure
(1) Shift transmission into PARK.
(2) Release cable adjuster lock tab (underneath the
steering column) (Fig. 74) to unlock cable.
(3) Raise vehicle.
(4) Disengage the cable eyelet from the transmis-
sion manual shift lever.
(5) Verify transmission shift lever is in PARK
detent by moving lever fully rearward. Last rearward
detent is PARK position.
(6) Verify positive engagement of transmission
park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.
(7) Snap the cable eyelet onto the transmission
manual shift lever.
Fig. 72 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 73 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
21 - 370 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
GEARSHIFT CABLE (Continued)

(15) Using Spring Compressor 8251, compress the
UD/OD balance piston and remove the snap-ring
from the input clutch hub (Fig. 80).(16) Remove the UD/OD balance piston and piston
return spring from the input clutch retainer (Fig. 81).
(17) Remove the underdrive piston from the input
clutch retainer (Fig. 81).
NOTE: Both the UD/OD balance piston and the
underdrive piston have seals molded onto them. If
the seal is damaged, do not attempt to install a new
seal onto the piston. The piston/seal must be
replaced as an assembly.
(18) Remove the input clutch retainer tapered
snap-ring.
(19) Separate input clutch retainer from input
clutch hub.
(20) Separate OD/reverse piston from input clutch
hub retainer (Fig. 81).
(21) Remove all seals and o-rings from the input
shaft and input hub. The o-rings on the input hub
are color coded. Be sure to make note of which o-ring
belongs in which location.
Fig. 80 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
21 - 376 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
INPUT CLUTCH ASSEMBLY (Continued)

ASSEMBLY
(1) Install all new seals and o-rings onto the input
shaft and input hub. The o-rings on the input hub
are color coded. Be sure to install the correct o-ring
in the correct location.
(2) Check the transmission lubrication check valve
located in the input shaft using shop air. The valve
should only allow air flow in one direction. If the
valve allows no air flow, or air flow in both direc-
tions, the valve will need to be replaced.(3) Lubricate all seals with MopartATF +4, Auto-
matic Transmission Fluid, prior to installation.
(4) Assemble the OD/reverse piston onto the input
clutch hub (Fig. 82).
(5) Assemble the input clutch retainer onto the
input clutch hub.
(6) Install the input clutch retainer tapered snap-
ring with tapered side up onto the input clutch hub.
Fig. 82 Input Clutch Assembly - Part I
1 - INPUT CLUTCH HUB 11 - UD CLUTCH
2 - O-RING SEALS 12 - PLATE
3 - SEAL 13 - CLUTCH RETAINER
4 - SNAP-RING 14 - SEAL
5 - SNAP-RING 15 - OD/REV PISTON
6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
7 - SNAP-RING 17 - SNAP-RING
8 - UD PISTON 18 - SEAL RINGS
9 - SPRING 19 - INPUT SHAFT
10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
21 - 378 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
INPUT CLUTCH ASSEMBLY (Continued)

(7) Install Piston Guides 8504 into the input clutch
retainer (Fig. 83) and onto the input clutch hub to
guide the inner and outer underdrive piston seals
into position.
(8) Install the underdrive piston into the input
clutch retainer and over the input clutch hub (Fig.
82).
(9) Install the UD/OD balance piston return spring
pack into the input clutch retainer.
(10) Install Piston Guide 8252 into the input
clutch retainer (Fig. 84) to guide the UD/OD balance
piston seal into position inside the underdrive piston.(11) Install the UD/OD balance piston into the
input clutch retainer and the underdrive piston.
(12) Using Spring Compressor 8251, compress the
UD/OD return spring pack and secure the piston in
place with the snap-ring (Fig. 85).
(13) Install the underdrive clutch pack into the
input clutch retainer (Fig. 82).
(14) Install the UD/OD reaction plate lower flat
snap-ring (Fig. 86). The correct snap-ring can be
identified by the two tabbed ears.
(15) Install the UD/OD reaction plate into the
input clutch retainer. The reaction plate is to be
installed with the big step down.
(16) Install the UD/OD reaction plate upper
tapered snap-ring with tapered side up.
(17) Install the input clutch assembly into Input
Clutch Pressure Fixture 8260 (Fig. 87). Mount a dial
indicator to the assembly, push down on the clutch
discs and zero the indicator against the underdrive
clutch discs (Fig. 88). Apply 20 psi of air pressure to
the underdrive clutch and record the dial indicator
reading. Measure and record UD clutch pack mea-
surement in four (4) places, 90É apart. Take average
of four measurements and compare with UD clutch
pack clearance specification. The correct clutch clear-
ance is 0.84-1.54 mm (0.033-0.061 in.). The reaction
plate is not selective. If the clutch clearance is not
within specification, replace the reaction plate along
with all the friction and steel discs.
(18) Install the overdrive clutch pack into the
input clutch retainer (Fig. 86). The overdrive steel
Fig. 83 Install Underdrive Piston Using Tool 8504
1 - TOOL 8504
Fig. 84 Install Balance Piston Using Tool 8252
1 - TOOL 8252
Fig. 85 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 379
INPUT CLUTCH ASSEMBLY (Continued)

separator plates can be identified by the lack of the
half-moon cuts in the locating tabs.
(19) Install the overdrive clutch wavy snap-ring
with the two tabbed ears into the input clutch
retainer.
(20) Install the OD/reverse reaction plate into the
input clutch retainer. The reaction plate is non-direc-
tional (Fig. 86).
(21) Install the OD/reverse reaction plate flat
snap-ring into the input clutch retainer.
(22) Mount a dial indicator to the assembly and
zero the indicator against the OD/reverse reactionplate (Fig. 89). Apply 20 psi of air pressure to the
overdrive clutch and record the dial indicator read-
ing. Measure and record OD clutch pack measure-
ment in four (4) places, 90É apart. Take average of
four measurements and compare with OD clutch
pack clearance specification.Verify that the clutch
clearance is 1.103-1.856 mm (0.043-0.073 in.). The
reaction plate is not selective. If the clutch clearance
is not within specification, replace the reaction plate
along with all the friction and steel discs.
(23) Install the reverse clutch pack into the input
clutch retainer (Fig. 86).
Fig. 86 Input Clutch Assembly - Part II
1 - BEARING NUMBER 3 10 - SNAP-RING (SELECT)
2 - OD HUB/SHAFT 11 - PLATE
3 - SNAP-RING (WAVE) 12 - DISC
4 - REV/OD REACTION PLATE 13 - OD CLUTCH
5 - BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
9 - REVERSE REACTION PLATE 18 - BEARING NUMBER 2
21 - 380 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
INPUT CLUTCH ASSEMBLY (Continued)

(24) Install the reverse reaction plate into the
input clutch retainer.
(25) Install the reverse reaction plate selective
snap-ring into the input clutch retainer.
(26) Mount a dial indicator to the assembly, push
down on the clutch discs, pull up on the reaction
plate to ensure the plate is properly seated and zero
the indicator against the reverse clutch discs (Fig.90). Apply 20 psi of air pressure to the reverse clutch
and record the dial indicator reading. Measure and
record Reverse clutch pack measurement in four (4)
places, 90É apart. Take average of four measurements
and compare with Reverse clutch pack clearance
specification. The correct clutch clearance is 0.58-1.47
mm (0.023-0.058 in.). Adjust as necessary. Install the
chosen snap-ring and re-measure to verify selection.
(27) Remove the reverse clutch pack from the
input clutch retainer.
Fig. 87 Input Clutch Assembly Mounted on Tool
8260
1 - INPUT CLUTCH ASSEMBLY
2 - TOOL 8260
Fig. 88 Measuring UD Clutch Clearance
1 - TOOL C-3339
2 - UNDERDRIVE CLUTCH PACK
Fig. 89 Measuring OD Clutch Clearance
1 - TOOL C-3339
2 - OD/REV REACTION PLATE
Fig. 90 Measuring Reverse Clutch Clearance
1 - TOOL C-3339
2 - REVERSE CLUTCH PACK
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 381
INPUT CLUTCH ASSEMBLY (Continued)

(28) Install the number 2 bearing onto the under-
drive hub with outer race against the hub with petro-
leum jelly.
(29) Install the underdrive hub into the input
clutch retainer.
(30) Install the number 3 bearing into the over-
drive hub with the outer race against the hub with
petroleum jelly.
(31) Install the overdrive hub into the input clutch
retainer.
(32) Install the number 4 bearing into the reverse
hub with outer race against the hub with petroleum
jelly.
(33) Install the reverse hub into the input clutch
retainer.
(34) Install the complete reverse clutch pack.
(35) Install the reverse reaction plate and snap-
ring.
(36) Push up on reaction plate to allow reverse
clutch to move freely.
INPUT SPEED SENSOR
DESCRIPTION
The Input and Output Speed Sensors are two-wire
magnetic pickup devices that generate AC signals as
rotation occurs. They are mounted in the left side of
the transmission case and are considered primary
inputs to the Transmission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on
how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC
voltage is generated and sent to the TCM. The TCM
interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal
in a similar fashion, though its coil is excited by rota-
tion of the rear planetary carrier lugs. The TCM
interprets this information as output shaft rpm.
The TCM compares the input and output speed
signals to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
The TCM also compares the input speed signal and
the engine speed signal to determine the following:
²Torque converter clutch slippage
²Torque converter element speed ratio
REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.(3) Remove the wiring connector from the input
speed sensor (Fig. 91).
(4) Remove the bolt holding the input speed sensor
to the transmission case.
(5) Remove the input speed sensor from the trans-
mission case.
INSTALLATION
(1) Install the input speed sensor into the trans-
mission case.
(2) Install the bolt to hold the input speed sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the input
speed sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
LINE PRESSURE (LP) SENSOR
DESCRIPTION
The TCM utilizes a closed-loop system to control
transmission line pressure. The system contains a
variable force style solenoid, the Pressure Control
Solenoid, mounted on the side of the solenoid and
pressure switch assembly. The solenoid is duty cycle
controlled by the TCM to vent the unnecessary line
pressure supplied by the oil pump back to the sump.
The system also contains a variable pressure style
sensor, the Line Pressure Sensor, which is a direct
input to the TCM. The line pressure solenoid moni-
tors the transmission line pressure and completes the
Fig. 91 Input Speed Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
21 - 382 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
INPUT CLUTCH ASSEMBLY (Continued)

feedback loop to the TCM. The TCM uses this infor-
mation to adjust its control of the pressure control
solenoid to achieve the desired line pressure.
OPERATION
The TCM calculates the desired line pressure
based upon inputs from the transmission and engine.
The TCM calculates the torque input to the trans-
mission and uses that information as the primary
input to the calculation. The line pressure is set to a
predetermined value during shifts and when the
transmission is in the PARK and NEUTRAL posi-
tions. This is done to ensure consistent shift quality.
During all other operation, the actual line pressure is
compared to the desired line pressure and adjust-
ments are made to the pressure control solenoid duty
cycle.
REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.
(3) Remove the wiring connector from the line
pressure sensor (Fig. 92).
(4) Remove the bolt holding the line pressure sen-
sor to the transmission case.
(5) Remove the line pressure sensor from the
transmission case.
INSTALLATION
(1) Install the line pressure sensor into the trans-
mission case.(2) Install the bolt to hold the line pressure sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the line pres-
sure sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
Fig. 92 Line Pressure Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 383
LINE PRESSURE (LP) SENSOR (Continued)

(5) Remove the overrunning clutch snap-ring (Fig.
94).
(6) Remove the spacer from the overrunning clutch
(Fig. 94).
(7) Separate the inner and outer races of the over-
running clutch (Fig. 94).
(8) Remove the overrunning clutch lower snap-ring
(Fig. 94).
(9) Using Spring Compressor 8285 and a suitable
shop press (Fig. 95), compress the low/reverse piston
Belleville spring and remove the split retaining ring
holding the Belleville spring into the low/reverse
clutch retainer.
(10) Remove the low/reverse clutch Belleville
spring and piston from the low/reverse clutch
retainer. Use 20 psi of air pressure to remove the pis-
ton if necessary.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
and low-reverse clutch retainer. Dry them with com-
pressed air after cleaning.
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 clutch retainer if the
clutch race, roller surface or inside diameter is
scored, worn or damaged.
ASSEMBLY
(1) Check the bleed orifice to ensure that it is not
plugged or restricted.
(2) Install a new seal on the low/reverse piston.
Lubricate the seal with MopartATF +4, Automatic
Transmission Fluid, prior to installation.
(3) Install the low/reverse piston into the low/re-
verse clutch retainer.
(4) Position the low/reverse piston Belleville spring
on the low/reverse piston.
(5) Using Spring Compressor 8285 and a suitable
shop press (Fig. 95), compress the low/reverse piston
Belleville spring and install the split retaining ring
to hold the Belleville spring into the low/reverse
clutch retainer.
(6) Install the lower overrunning clutch snap-ring
(Fig. 94).
(7) Assemble the inner and outer races of the over-
running clutch (Fig. 94).
(8) Position the overrunning clutch spacer on the
overrunning clutch.
(9) Install the upper overrunning clutch snap-ring
(Fig. 94).
(10) Assemble and install the low/reverse clutch
pack into the low/reverse clutch retainer (Fig. 93).
(11) Install the low/reverse reaction plate into the
low/reverse clutch retainer (Fig. 93). The reaction
plate is directional and must be installed with the
flat side down.
(12) Install the low/reverse clutch pack snap-ring
(Fig. 93). The snap-ring is selectable and should be
chosen to give the correct clutch pack clearance.
Fig. 94 Overrunning Clutch
1 - SNAP-RING
2 - OUTER RACE
3 - OVERRUNNING CLUTCH
4 - SPACER
Fig. 95 Compress Low/Reverse Belleville Spring
Using Tool 8285
1 - PRESS
2 - TOOL 8285
3 - BELLEVILLE SPRING
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 385
LOW/REVERSE CLUTCH (Continued)

(13) Measure the low/reverse clutch pack clearance
and adjust as necessary. The correct clutch clearance
is 1.00-1.74 mm (0.039-0.075 in.).
(14) Install the overrunning clutch into the low/re-
verse clutch retainer making sure that the index
splines are aligned with the retainer.
(15) Install the overrunning clutch inner snap-
ring.
OIL PUMP
DESCRIPTION
The oil pump (Fig. 96) is located at the front of the
transmission inside the bell housing and behind the
transmission front cover. The oil pump consists of
two independent pumps (Fig. 97), a number of valves
(Fig. 98), a front seal (Fig. 99), and a bolt on reaction
shaft. The converter clutch switch and regulator
valves, pressure regulator valve, and converter pres-
sure limit valve are all located in the oil pump valve
body.
OPERATION
As the torque converter rotates, the converter hub
rotates the oil pump drive gear. As the drive gear
rotates both driven gears, a vacuum is created when
the gear teeth come out of mesh. This suction draws
fluid through the pump inlet from the oil pan. As the
gear teeth come back into mesh, pressurized fluid is
forced into the pump outlet and to the oil pump
valves.
At low speeds, both sides of the pump supply fluid
to the transmission. As the speed of the torque con-verter increases, the flow from both sides increases
until the flow from the primary side alone is suffi-
cient to meet system demands. At this point, the
check valve located between the two pumps closes.
The secondary side is shut down and the primary
side supplies all the fluid to the transmission.
CONVERTER CLUTCH SWITCH VALVE
The converter clutch switch valve is used to control
the hydraulic pressure supplied to the front (OFF)
side of the torque converter clutch.
Fig. 96 Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 97 Oil Pump Gears
1 - PUMP HOUSING
2 - DRIVE GEAR
3 - DRIVEN GEARS
Fig. 98 Oil Pump Valves
1 - TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE
2 - TORQUE CONVERTER CLUTCH CONTROL VALVE
3 - TORQUE CONVERTER CLUTCH SWITCH VALVE
4 - PUMP VALVE BODY
5 - PRESSURE REGULATOR VALVE
6 - TORQUE CONVERTER CLUTCH LIMIT VALVE
21 - 386 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
LOW/REVERSE CLUTCH (Continued)