gear DODGE RAM 1500 1998 2.G Workshop Manual

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
CAUTION: Before attempting any repair on a RFE
automatic transmission, check for Diagnostic Trou-
ble Codes with the DRBTscan tool.
Transmission malfunctions may be caused by these
general conditions:
²Poor engine performance
²Improper adjustments
²Hydraulic malfunctions
²Mechanical malfunctions
²Electronic malfunctions
Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or if more diagnosis is necessary. If the
problem persists after the preliminary tests and cor-
rections are completed, hydraulic pressure checks
should be performed.
DIAGNOSIS AND TESTING - PRELIMINARY
Two basic procedures are required. One procedure
for vehicles that are drivable and an alternate proce-
dure for disabled vehicles (will not back up or move
forward).
VEHICLE IS DRIVABLE
(1) Check for transmission fault codes using DRBt
scan tool.
(2) Check fluid level and condition.
(3) Adjust gearshift cable if complaint was based
on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
(5) Perform hydraulic pressure test if shift prob-
lems were noted during road test.(6) Perform air-pressure test to check clutch oper-
ation.
VEHICLE IS DISABLED
(1) Check fluid level and condition.
(2) Check for broken or disconnected gearshift
cable.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmis-
sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmis-
sion and check for damaged driveplate, converter,
oil pump, or input shaft.
(c) If propeller shaft does not turn and transmis-
sion is not noisy, perform hydraulic-pressure test to
determine if problem is hydraulic or mechanical.
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testing, be sure the fluid level and con-
trol cable adjustments have been checked and
adjusted if necessary. Verify that all diagnostic trou-
ble codes have been resolved.
Observe engine performance during the road test.
A poorly tuned engine will not allow accurate analy-
sis of transmission operation.
Operate the transmission in all gear ranges. Check
for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means
clutch, overrunning clutch, or line pressure problems.
A slipping clutch can often be determined by com-
paring which internal units are applied in the vari-
ous gear ranges. The Clutch Application charts
provide a basis for analyzing road test results.
21 - 314 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST
An accurate tachometer and pressure test gauges
are required. Test Gauge C-3293-SP has a 300 psi
range and is used at all locations where pressures
exceed 100 psi.
Pressure Test Port Locations
Only two pressure ports are supplied on the trans-
mission case. The torque converter clutch apply and
release ports are located on the right side of the
transmission case (Fig. 2).
To determine the line pressure, there are two avail-
able methods. The DRBtscan tool can be used to
read line pressure from the line pressure sensor. The
second method is to install Line Pressure Adapter
8259 (Fig. 4) into the transmission case and then
install the pressure gauge and the original sensor
into the adapter. This will allow a comparison of the
DRBtreadings and the gauge reading to determine
the accuracy of the line pressure sensor. The DRBt
line pressure reading should match the gauge read-
ing within  10 psi.
In order to access any other pressure tap locations,
the transmission oil pan must be removed, the pres-
sure port plugs removed and Valve Body Pressure
Tap Adapter 8258-A (Fig. 5) installed. The extensions
supplied with Adapter 8258-A will allow the installa-
tion of pressure gauges to the valve body. Refer to
(Fig. 3) for correct pressure tap location identifica-
tion.
TEST PROCEDURE
All pressure readings should be taken with the
transmission fluid level full, transmission oil at the
normal operating temperature, and the engine at
1500 rpm. Check the transmission for proper opera-
tion in each gear position that is in question or if a
specific element is in question, check the pressure
readings in at least two gear positions that employ
that element. Refer to the Hydraulic Schematics at
the rear of this section to determine the correct pres-
sures for each element in a given gear position.
Fig. 2 Torque Converter Pressure Locations
1 - TCC RELEASE
2 - TO COOLER
3 - TCC APPLY
4 - FROM COOLER
5 - LINE PRESSURE SENSOR
Fig. 3 Pressure Tap Locations
Fig. 4 Line Pressure Adapter 8259
1 - LINE PRESSURE SENSOR PORT
2 - LINE PRESSURE SENSOR
3 - TOOL 8259
4 - PRESSURE TAP
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

NOTE: The 45RFE/545RFE utilizes closed loop con-
trol of pump line pressure. The pressure readings
may therefore vary greatly but should always follow
line pressure.
Some common pressures that can be measured to
evaluate pump and clutch performance are the
upshift/downshift pressures, garage shift pressures,
and TCC pressure. The upshift/downshift pressure
for all shifts are shown in UPSHIFT PRESSURES
and DOWNSHIFT PRESSURES. In-gear maximum
pressure for each gear position is shown in IN-GEAR
PRESSURES. The garage shift pressure when per-
forming a N-R shift is 220 psi for 3.7L/4.7L equipped
vehicles and 250 psi for 5.7L equipped vehicles. The
garage shift pressure for the R-N shift is 120 psi. The
garage shift pressure for the N-1 shift is 135 psi for
3.7L/4.7L equipped vehicles and 165 psi for 5.7L
equipped vehicles. Torque converter lock-up pressure
is 120 psi for 3.7L/4.7L equipped vehicles and 125 psi
for 5.7L equipped vehicles.
UPSHIFT PRESSURES
ENGINE 1-2 2-3 2prime-3 3-4 2prime-4 2-5 3-5 4-5
5.7L150 125 125 135 135 135 135 135
3.7L/
4.7L120 120 120 120 120 120 120 130
DOWNSHIFT PRESSURES
ENG-
INE5-
45-3 5-2 4-34-2
prime3-23-2
prime2
prime-
12-
13-1
5.7L135 135 135 135 135 135 135 135 135 135
3.7L/
4.7L120 120 120 120 120 120 120 120 120 120
IN-GEAR PRESSURES
ENGINE 1 22
prime345NEUT-
RALREV-
ERSE
5.7L160 135 135 135 135 135 120 250
3.7L/
4.7L135 120 120 120 120 120 120 220
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION
Air-pressure testing can be used to check transmis-
sion clutch operation. The test can be conducted with
the transmission either in the vehicle or on the work
bench, as a final check.
Air-pressure testing requires that the oil pan and
valve body be removed from the transmission. The
clutch apply passages are shown (Fig. 6).
NOTE: The air supply which is used must be free of
moisture and dirt. Use a pressure of 30 psi to test
clutch operation.
Apply air pressure at each port. If the clutch is
functioning, a soft thump will be heard as the clutch
Fig. 5 Valve Body Pressure Tap Adapter 8258-A
1 - 45RFE TRANSMISSION
2 - TOOL 8258-A
Fig. 6 Air Pressure Test Passages
1 - LOW REVERSE CLUTCH
2 - 4TH CLUTCH
3 - 2ND CLUTCH
4 - OVERDRIVE CLUTCH
5 - UNDERDRIVE CLUTCH
6 - REVERSE CLUTCH
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 317
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
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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)

specification, the reaction plate, all the friction discs,
and steels must be replaced.
(16) Remove the 4C retainer/bulkhead and all of
the 2C clutch components from the transmission
case.
(17) Install the low/reverse clutch assembly (Fig.
36). Make sure that the oil feed hole points toward
the valve body area and that the bleed orifice is
aligned with the notch in the rear of the transmis-
sion case.
(18) Install the snap-ring to hold the low/reverse
clutch retainer into the transmission case (Fig. 36).
The snap-ring is tapered and must be installed with
the tapered side forward. Once installed, verify that
the snap-ring is fully seated in the snap-ring groove.
(19) Air check the low/reverse clutch and verify
correct overrunning clutch operation.
(20) Install the number 12 bearing over the output
shaft and against the rear planetary gear set. The
flat side of the bearing goes toward the planetary
gearset and the raised tabs on the inner race should
face the rear of the transmission.
(21) Install the reverse/input planetary assembly
through the low/reverse clutch assembly (Fig. 37).
(22) Install the park sprag onto the output shaft
(Fig. 38).
Fig. 38 Install Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 36 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 37 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(23) Install the snap-ring to hold the park sprag
onto the output shaft (Fig. 39).
(24) Install the 2C reaction plate into the trans-
mission case (Fig. 40).
(25) Install the 2C clutch pack into the transmis-
sion case (Fig. 40).
(26) Install the number 8 bearing inside the reac-
tion carrier with the outer race against the reaction
planetary carrier.
(27) Install the reaction planetary gear set and the
number 9 bearing, with the inner race against the
reaction planetary carrier, into the transmission case
(Fig. 41).(28) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 40).
(29) Install the reaction sun gear into the reaction
planetary gear set.Make surethe small shoulder is
facing the front of the transmission (Fig. 41).
(30) Install the number 7 bearing onto the reaction
sun gear with the inner race against the sun gear
(Fig. 41).
Fig. 39 Install Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 40 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 329
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

Fig. 41 Install 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 - 330 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(31) Install the output shaft selective thrust plate
onto the reaction annulus with the oil grooves facing
the annulus gear and the tabs and notches aligned as
shown in (Fig. 42).
(32) Install the number 6 bearing against the out-
put shaft selective thrust plate with the flat side
against the thrust plate (Fig. 41) and the raised tabs
on the inner race facing the front of the transmis-
sion.
(33) Install the reaction annulus into the reaction
planetary gear set (Fig. 41).
(34) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the
reaction annulus during the installation of the 4C
retainer/bulkhead to ease installation.
(35) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case (Fig. 43) with
the taper toward the front of the case. Make sure
that the open ends of the snap-ring are located in the
case opening toward the valve body area.
(36) Air check the 2C and 4C clutch operation.
(37) 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. 44). The correct output shaft end-play is
0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary.
Install the chosen output shaft selective thrust plate
and re-measure end-play to verify selection.
(38) Apply a bead of RTV silicone and install the
extension/adapter housing onto the transmission
case.(39) Install and torque the bolts to hold the exten-
sion/adapter housing onto the transmission case. The
correct torque is 54 N´m (40 ft.lbs.).
(40) Install the number 5 bearing and selective
thrust plate onto the 4C retainer/bulkhead (Fig. 45).
Be sure that the outer race of the bearing is against
the thrust plate.
(41) Install the input clutch assembly into the
transmission case (Fig. 45). Make sure that the input
clutch assembly is fully installed by performing a
Fig. 42 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 43 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 44 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 331
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)