FRONT HUB DODGE RAM 1500 1998 2.G Manual PDF

TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
²Leaks at the weld joint around the outside diam-
eter weld.
²Leaks at the converter hub weld.
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Tighten front band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out when oil pump is
removed.
(3) Remove oil pump and remove pump seal.
Inspect pump housing drainback and vent holes for
obstructions. Clear holes with solvent and wire.(4) Inspect pump bushing and converter hub. If
bushing is scored, replace it. If converter hub is
scored, either polish it with crocus cloth or replace
converter.
(5) Install new pump seal, O-ring, and gasket.
Replace oil pump if cracked, porous or damaged in
any way. Be sure to loosen the front band before
installing the oil pump, damage to the oil pump seal
may occur if the band is still tightened to the front
clutch retainer.
(6) Loosen kickdown lever pin access plug three
turns. Apply LoctiteŸ 592, or PermatextNo.2to
plug threads and tighten plug to 17 N´m (150 in. lbs.)
torque.
(7) Adjust front band.
(8) Lubricate pump seal and converter hub with
transmission fluid or petroleum jelly and install con-
verter.
(9) Install transmission and converter housing
dust shield.
(10) Lower vehicle.
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS
The diagnosis charts provide additional reference
when diagnosing a transmission fault. The charts
provide general information on a variety of transmis-
sion, overdrive unit and converter clutch fault condi-
tions.
The hydraulic flow charts in the Schematics and
Diagrams section of this group, outline fluid flow and
hydraulic circuitry. Circuit operation is provided for
PARK, NEUTRAL, FIRST, SECOND, THIRD,
FOURTH, MANUAL FIRST, MANUAL SECOND,
and REVERSE gear ranges. Normal working pres-
sures are also supplied for each of the gear ranges.
Fig. 11 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
DRAUTOMATIC TRANSMISSION - 48RE 21 - 145
AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS. 1. Fluid Lines and Fittings Loose/
Leaks/Damaged.1. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
2. Fill Tube (where tube enters case)
Leaks/Damaged.2. Replace tube seal. Inspect tube for
cracks in fill tube.
3. Pressure Port Plug Loose
Loose/Damaged.3. Tighten to correct torque. Replace plug
or reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.5. Replace shaft seal.
6. Rear Bearing Access Plate Leaks. 6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.8. Replace gasket.
9. Park/Neutral Switch, or
Transmission Range Sensor
Leaks/Damaged.9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION IN
FOURTH GEAR ONLY1. Overdrive Clutch Discs, Plates or
Snap Rings Damaged.1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.2. Remove and disassemble unit. Replace
either thrust bearing if damaged.
3. Output Shaft Bearings Scored/
Damaged.3. Remove and disassemble unit. Replace
either bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning Clutch
Rollers Worn/Scored.5. Remove and overhaul overdrive unit.
DRAUTOMATIC TRANSMISSION - 48RE 21 - 157
AUTOMATIC TRANSMISSION - 48RE (Continued)

(18) Squeeze front band together slightly and slide
band over front clutch retainer and out of case (Fig.
28).
(19) Remove front and rear clutch assemblies as a
unit (Fig. 29).(20) Remove front band reaction pin and lever.
Start pin through lever and out of case bore with
drift or punch. Then use pencil magnet to withdraw
pin completely (Fig. 30).
(21) Remove intermediate shaft thrust washer. Tri-
angular shaped washer will either be on shaft pilot
hub or in rear clutch retainer (Fig. 31).
Fig. 29 Removing Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
Fig. 30 Front Band Lever And Pin
1 - BAND LEVER
2 - USE PENCIL MAGNET TO REMOVE REACTION PIN
Fig. 31 Intermediate Shaft Thrust Washer
1 - THRUST WASHER
2 - INTERMEDIATE SHAFT PILOT HUB
Fig. 28 Front Band Removal
1 - FRONT BAND
2 - FRONT CLUTCH RETAINER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 163
AUTOMATIC TRANSMISSION - 48RE (Continued)

(27) Note that overrunning clutch race will remain
on splines of low-reverse drum after removal (Fig.
36).The race is a permanent press fit on the
hub splines. Do not attempt to remove the race.
(28) Remove overrunning clutch assembly (Fig.
37). Assembly can be removed without displacing
rollers and springs if care is exercised. Note position
of rollers and springs for assembly reference.
(29) Remove rear band adjusting lever and reac-
tion pin.
(30) Remove rear band.
(31) Compress front servo rod guide with large
C-clamp and Tool C-4470, or Compressor Tool
C-3422-B (Fig. 38). Compress guide only enough to
permit snap-ring removal (about 1/8 in.).
(32) Remove servo piston snap-ring (Fig. 38).
Unseat one end of ring. Then carefully work removal
tool around back of ring until free of ring groove.
Exercise caution when removing snap-ring.
Servo bore can be scratched or nicked if care is
not exercised.
Fig. 38 Front Servo Retaining Snap-Ring
1 - C-CLAMP
2 - FRONT SERVO ROD GUIDE
3 - SNAP-RING
4 - TOOL C-4470
Fig. 36 Overrunning Clutch Race Position On
Low-Reverse Drum
1 - OVERRUNNING CLUTCH RACE
2 - LOW-REVERSE DRUM
Fig. 37 Overrunning Clutch
1 - CLUTCH CAM
2 - OVERRUNNING CLUTCH ASSEMBLY
DRAUTOMATIC TRANSMISSION - 48RE 21 - 165
AUTOMATIC TRANSMISSION - 48RE (Continued)

(7) Bottom front servo piston in bore and install
servo spring.
(8) Install front servo piston rod guide as follows:
(a) Place Tool SP-5560 (or similar size tool) on
guide and position C-clamp on tool and case (Fig.
44).
(b) Slowly compress rod guide while simulta-
neously easing seal ring into bore with suitable
tool.
(9) Install rod guide snap-ring (Fig. 44).
OVERRUNNING CLUTCH, REAR BAND, AND
LOW-REVERSE DRUM
(1) Install overrunning clutch components if not
yet installed.
(2) Position rear band reaction pin and band in
case. Be sure that the twin lugs on the band are
seated against the reaction pin.
(3) Install low-reverse drum. Slide drum through
rear band, onto piston retainer hub and into engage-
ment with overrunning clutch and race.
(4) Install thrust washer in low-reverse drum spot-
face (Fig. 45). Use petroleum jelly to hold washer in
place.
(5) Install snap-ring that secures low-reverse drum
to piston retainer hub (Fig. 45).
(6) Insert the rear band pivot pin part way into
the case.(7) Install rear band adjusting lever and pivot pin.
Be sure lever and the single lug on the band are
aligned and engaged before seating band pivot pin in
case.
Fig. 43 Front Servo Piston
1 - USE SUITABLE TOOL TO HELP SEAT PISTON RING
2 - FRONT SERVO PISTON
Fig. 44 Front Servo Rod Guide And Snap Ring
1 - C-CLAMP
2 - ROD GUIDE
3 - SMALL SCREWDRIVER
4 - ROD GUIDE SNAP-RING
5 - TOOL SP-5560
Fig. 45 Low-Reverse Drum Snap Ring
1 - LOW-REVERSE DRUM
2 - TABBED WASHER
3 - SNAP-RING
21 - 168 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

PLANETARY GEARTRAIN, FRONT/REAR CLUTCH,
AND FRONT BAND
(1) Remove Alignment Shaft 6227-2, if installed
previously.
(2) Install assembled intermediate shaft and plan-
etary geartrain (Fig. 46).Support shaft carefully
during installation. Do not allow shaft bearing/
bushing surfaces to become nicked or
scratched.
(3) Lubricate intermediate shaft thrust plate with
petroleum jelly and install plate on shaft pilot hub
(Fig. 47).
(4) Check input shaft front seal rings, fiber thrust
washer and rear seal ring (Fig. 48). Be sure the ends
of rear seal ring are hooked together and diagonal
cut ends of front seal rings are firmly seated against
each other as shown. Lubricate seal rings with petro-
leum jelly after checking them.
(5) Assemble front and rear clutches (Fig. 49).
Align lugs on front clutch discs. Mount front clutch
on rear clutch. Turn front clutch retainer back and
forth until front clutch discs are fully seated on rear
clutch splined hub.
Fig. 46 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN
ASSEMBLY
Fig. 47 Intermediate Shaft Thrust Plate
1 - SHAFT THRUST PLATE
2 - INTERMEDIATE SHAFT PILOT HUB
Fig. 48 Input Shaft Seal Ring And Thrust Washer
1 - TORLONTFRONT SEAL RINGS
2 - INPUT SHAFT
3 - REAR SEAL RING
4 - THRUST WASHER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 169
AUTOMATIC TRANSMISSION - 48RE (Continued)

(6) Install intermediate shaft thrust washer in hub
of rear clutch retainer (Fig. 50). Use petroleum jelly
to hold washer in place. Position washer so grooves
are facing outward.Washer only fits one way in
clutch retainer hub.
(7) Place transmission case in upright position, or
place blocks under front end of transmission repair
stand to tilt case rearward. This makes it easier to
install front/rear clutch assembly.
(8) Align discs in rear clutch. Then install and
engage assembly in front planetary and driving shell
(Fig. 51). Turn clutch retainers back and forth until
both clutches are seated.
(9) Position front band lever in case and over servo
rod guide. Then install front band lever pin in case
and slide it through lever.
(10) Coat threads of front band pin access plug
with sealer and install it in case. Tighten plug to 17
N´m (13 ft. lbs.) torque.
Fig. 50 Intermediate Shaft Thrust Washer
1 - BE SURE WASHER GROOVES FACE OUT AS SHOWN
2 - REAR CLUTCH RETAINER HUB
3 - SHAFT THRUST WASHER
Fig. 51 Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
Fig. 49 Assembling Front And Rear Clutches
1 - FRONT CLUTCH ASSEMBLY
2 - REAR CLUTCH ASSEMBLY
3 - REAR CLUTCH SPLINED HUB
21 - 170 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

(11) Slide front band over front clutch retainer and
install front band strut and anchor (Fig. 52).
(12) Tighten front band adjusting screw until band
is tight on clutch retainer. This will hold clutches in
place while oil pump is being installed.Verify that
front/rear clutch assembly is still properly
seated before tightening band.
OIL PUMP
(1) Install oil pump Pilot Studs C-3288-B in case
(Fig. 53).(2) Install new oil pump gasket on pilot studs and
seat it in case. Be sure gasket is properly aligned
with fluid passages in case (Fig. 53).
(3) Coat the reaction shaft thrust washer with
petroleum jelly to hold it in place. Then install
washer over reaction shaft hub and seat it on pump
(Fig. 54).
CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
Fig. 53 Oil Pump Gasket And Pilot Studs
1 - OIL PUMP GASKET
2 - PILOT STUDS C-3288-B
Fig. 54 Front Clutch Thrust Washer Installation
1 - THRUST WASHER
2 - CHAMFERED SIDE OF WASHER BORE GOES TOWARD
PUMP
Fig. 55 Reaction Shaft Seal Ring And Thrust Washer
1 - SEAL RINGS
2 - REACTION SHAFT SUPPORT
3 - THRUST WASHER (FIBER)
Fig. 52 Front Band And Linkage
1 - LEVER
2 - STRUT
3 - ANCHOR
4 - FRONT BAND
DRAUTOMATIC TRANSMISSION - 48RE 21 - 171
AUTOMATIC TRANSMISSION - 48RE (Continued)

(9) Install the two screws to hold the TRS to the
mounting bracket. Tighten the screws to 5 N´m (45
in.lbs.).
(10) Verify proper sensor operation (Fig. 62).
(11) Move the transmission manual shaft lever to
the PARK position.
(12) Install torque converter. Use C-clamp or metal
strap to hold converter in place for installation.
BAND ADJUSTMENT AND FINAL
(1) Adjust front and rear bands as follows:
(a) Loosen locknut on each band adjusting screw
4-5 turns.
(b) Tighten both adjusting screws to 8 N´m (72
in. lbs.).
(c) Back off front band adjusting screw 1-3/4
turns.
(d) Back off rear band adjusting screw 3 turns.
(e) Hold each adjusting screw in position and
tighten locknut to 34 N´m (25 ft. lbs.) torque.
(2) Install magnet in oil pan. Magnet seats on
small protrusion at corner of pan.
(3) Position new oil pan gasket on case and install
oil pan. Tighten pan bolts to 13.6 N´m (125 in. lbs.).
(4) Install throttle valve and shift selector levers
on valve body manual lever shaft.
(5) Apply small quantity of dielectric grease to ter-
minal pins of solenoid case connector and neutral
switch.
(6) Fill transmission with recommended fluid.
INSTALLATION
(1) Check torque converter hub inner and outer
diameters and hub drive notches for sharp edgesburrs, scratches, or nicks. Polish the hub and notches
with 320/400 grit paper and crocus cloth if necessary.
The hub must be smooth to avoid damaging pump
seal at installation.
(2) Lubricate pocket in the rear oil pump seal lip
with transmission fluid.
(3) Lubricate converter pilot hub of the crankshaft
with a light coating of MopartHigh Temp Grease.
(4) Align and install converter in oil pump.
(5) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(6) Check converter seating with steel scale and
straightedge (Fig. 63). Surface of converter lugs
should be 19mm (0.75 in.) to rear of straightedge
when converter is fully seated.
(7) Temporarily secure converter with C-clamp.
(8) Position transmission on jack and secure it
with chains.
(9) Check condition of converter driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Raise transmission and align converter with
drive plate and converter housing with engine block.
(11) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
engine block dowels.
(12) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft.
Fig. 62 Transmission Range Sensor Operation
1 - NEUTRAL CONTACT
2 - MANUAL LEVER AND SENSOR PLUNGER IN REVERSE
POSITION
3 - PARK CONTACT
4 - TRANSMISSION RANGE SENSOR
Fig. 63 Checking Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
21 - 174 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.150-1.22
mm0.006-0.048
in.
Input shaft end play 0.86-2.13
mm0.034-0.084
in.
Clutch pack clearance/
Front.2.5-4.09
mm0.098-0.161
in.
Clutch pack clearance/
Rear.0.635-0.914
mm0.025-0.036
in.
Front clutch 5 discs
Rear clutch 4 discs
Overdrive clutch 5(STD) OR 6(Diesel HO)
discs
Direct clutch 23 Single Sided discs
Band adjustment from
72 in. lbs.
Front band Back off 1 3/4 turns
Rear band Back off 3 turns
Recommended fluid MoparTAT F + 4GEAR RATIOS
1ST GEAR 2.45:1
2ND GEAR 1.45:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.20:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Component Metric Inch
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
2.15 mm 0.084 in.
2.59 mm 0.102 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) 1.5-1.6 mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.75-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.085 in.
Rear clutch pack snap-ring 1.5-1.6 mm 0.060-0.062 in.
1.9-1.95 mm 0.074-0.076 in.
Planetary geartrain snap-ring (at front of output shaft) 1.4-1.5 mm 0.055-0.059 in.
1.6-1.7 mm 0.062-0.066 in.
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures Intermediate shaft spacer
DRAUTOMATIC TRANSMISSION - 48RE 21 - 189
AUTOMATIC TRANSMISSION - 48RE (Continued)