DODGE RAM 2001 Service Repair Manual

DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS
The overdrive off switch, valve body solenoid, case
connectors and related wiring can all be tested with
a 12 volt test lamp or a volt/ohmmeter. Check conti-
nuity of each component when diagnosis indicates
this is necessary.
Switch and solenoid continuity should be checked
whenever the transmission fails to shift into fourth
gear range.
REMOVAL
(1) Using a plastic trim tool, remove the overdrive
off switch retainer from the shift lever (Fig. 115).
(2) Pull the switch outwards to release it from the
connector in the lever (Fig. 116)
INSTALLATION
NOTE: There is enough slack in the wire to pull out
the connector from the lever.
(1) Pull the connector out of the lever just enough
to grasp it.
CAUTION: Be careful not to bend the pins on the
overdrive off switch. Use care when installing the
switch, as it is not indexed, and can be accidentally
installed incorrectly.
(2) Install the overdrive off switch into the connec-
tor (Fig. 117)
(3) Push the overdrive off switch and wiring into
the shift lever.
(4) Install the overdrive off switch retainer onto
the shift lever.
Fig. 114 Overdrive Off Switch
Fig. 115 Overdrive Off Switch Retainer
1 - GEAR SHIFT LEVER
2 - OVERDRIVE OFF SWITCH RETAINER
3 - PLASTIC TRIM TOOL
Fig. 116 Remove the Overdrive Off Switch
1 - GEAR SHIFT LEVER
2 - OVERDRIVE OFF SWITCH
Fig. 117 Install the Overdrive Off Switch
1 - GEAR SHIFT LEVER
2 - OVERDRIVE OFF SWITCH WIRING CONNECTOR
3 - OVERDRIVE OFF SWITCH
21 - 386 AUTOMATIC TRANSMISSION - 44REBR/BE
OVERDRIVE SWITCH (Continued)

OVERDRIVE UNIT
REMOVAL
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Remove transfer case, if equipped.
(4) Mark propeller shaft universal joint(s) and axle
pinion yoke, or the companion flange and flange
yoke, for alignment reference at installation, if necc-
esary.
(5) Disconnect and remove the rear propeller shaft,
if necessary. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(6) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(7) If overdrive unit had malfunctioned, or if fluid
is contaminated, remove entire transmission. If diag-
nosis indicated overdrive problems only, remove just
the overdrive unit.
(8) Support transmission with transmission jack.
(9) Remove bolts attaching overdrive unit to trans-
mission (Fig. 118).
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(10) Carefully work overdrive unit off intermediate
shaft. Do not tilt unit during removal. Keep it as
level as possible.
(11) If overdrive unit does not require service,
immediately insert Alignment Tool 6227-2 in splines
of planetary gear and overrunning clutch to preventsplines from rotating out of alignment. If misalign-
ment occurs, overdrive unit will have to be disassem-
bled in order to realign splines.
(12) Remove and retain overdrive piston thrust
bearing. Bearing may remain on piston or in clutch
hub during removal.
(13) Position drain pan on workbench.
(14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal
fragments. If fluid contains these items, overhaul will
be necessary.
(16) If overdrive unit does not require any service,
leave alignment tool in position. Tool will prevent
accidental misalignment of planetary gear and over-
running clutch splines.
DISASSEMBLY
(1) Remove transmission speed sensor and O-ring
seal from overdrive case (Fig. 119).
(2) Remove overdrive piston thrust bearing (Fig.
120).
Fig. 118 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
Fig. 119 Transmission Speed Sensor Removal
1 - SOCKET AND WRENCH
2 - SPEED SENSOR
3 - O-RING
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 387

OVERDRIVE PISTON
(1) Remove overdrive piston thrust plate (Fig.
121). Retain thrust plate. It is a select fit part and
may possibly be reused.(2) Remove intermediate shaft spacer (Fig. 122).
Retain spacer. It is a select fit part and may possibly
be reused.
(3) Remove overdrive piston from retainer (Fig.
123).
Fig. 120 Overdrive Piston Thrust Bearing Removal
1 - THRUST BEARING
2 - OVERDRIVE PISTON
3 - THRUST PLATE
Fig. 121 Overdrive Piston Thrust Plate Removal
1 - OVERDRIVE PISTON
2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig. 122 Intermediate Shaft Spacer Location
1 - INTERMEDIATE SHAFT
2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
Fig. 123 Overdrive Piston Removal
1 - PISTON RETAINER
2 - OVERDRIVE PISTON
21 - 388 AUTOMATIC TRANSMISSION - 44REBR/BE
OVERDRIVE UNIT (Continued)

OVERDRIVE CLUTCH PACK
(1) Remove overdrive clutch pack wire retaining
ring (Fig. 124).
(2) Remove overdrive clutch pack (Fig. 125).
NOTE: The 44RE transmission has four(4) clutch
discs and three(3) clutch plates.
(3) Note position of clutch pack components for
assembly reference.
OVERDRIVE GEARTRAIN
(1) Remove overdrive clutch wave spring (Fig.
126).
(2) Remove overdrive clutch reaction snap-ring
(Fig. 127). Note that snap-ring is located in same
groove as wave spring.
(3) Remove TorxŸ head screws that attach access
cover and gasket to overdrive case (Fig. 128).
Fig. 124 Removing Overdrive Clutch Pack Retaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 125 Overdrive Clutch Pack Removal
1 - OVERDRIVE CLUTCH PACK
Fig. 126 Overdrive Clutch Wave
1 - WAVE SPRING
Fig. 127 Overdrive Clutch Reaction Snap-Ring
Removal
1 - REACTION RING
2 - CLUTCH HUB
Fig. 128 Access Cover Screw Removal
1 - TORXŸ SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 389
OVERDRIVE UNIT (Continued)

(4) Remove access cover and gasket (Fig. 129).
(5) Expand output shaft bearing snap-ring with
expanding-type snap-ring pliers. Then push output
shaft forward to release shaft bearing from locating
ring (Fig. 130).
(6) Lift gear case up and off geartrain assembly
(Fig. 131).
(7) Remove snap-ring that retains rear bearing on
output shaft.
(8) Remove rear bearing from output shaft (Fig.
132).
Fig. 129 Access Cover And Gasket Removal
1 - ACCESS COVER AND GASKET
Fig. 130 Releasing Bearing From Locating Ring
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 131 Removing Gear Case From Geartrain
Assembly
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 132 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
21 - 390 AUTOMATIC TRANSMISSION - 44REBR/BE
OVERDRIVE UNIT (Continued)

DIRECT CLUTCH, HUB AND SPRING
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXI-
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrain assembly in shop press (Fig.
133).
(2) Position Compressor Tool 6227-1 on clutch hub
(Fig. 133). Support output shaft flange with steel
press plates as shown and center assembly under
press ram.(3) Apply press pressure slowly. Compress hub and
spring far enough to expose clutch hub retaining ring
and relieve spring pressure on clutch pack snap-ring
(Fig. 133).
(4) Remove direct clutch pack snap-ring (Fig. 134).
(5) Remove direct clutch hub retaining ring (Fig.
135).
(6) Release press load slowly and completely (Fig.
136).
(7) Remove Special Tool 6227-1. Then remove
clutch pack from hub (Fig. 136).
Fig. 133 Geartrain Mounted In Shop Press
1 - PRESS RAM
2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL)
3 - CLUTCH HUB
4 - PLATES
5 - PRESS BED
6 - SPECIAL TOOL 6227-1
Fig. 134 Direct Clutch Pack Snap-Ring Removal
1 - CLUTCH HUB
2 - SPECIAL TOOL 6227-1
3 - DIRECT CLUTCH PACK SNAP-RING
4 - PRESS PLATES
5 - CLUTCH DRUM
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 391
OVERDRIVE UNIT (Continued)

GEARTRAIN
(1) Remove direct clutch hub and spring (Fig. 137).
(2) Remove sun gear and spring plate. Then
remove planetary thrust bearing and planetary gear
(Fig. 138).
Fig. 135 Direct Clutch Hub Retaining Ring Removal
1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RING
3 - PRESS BED
4 - PRESS PLATES
Fig. 136 Direct Clutch Pack Removal
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH HUB
3 - DIRECT CLUTCH PACK
Fig. 137 Direct Clutch Hub And Spring Removal
1 - DIRECT CLUTCH SPRING
2 - DIRECT CLUTCH HUB
Fig. 138 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1 - PLANETARY GEAR
2 - PLANETARY THRUST BEARING
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
21 - 392 AUTOMATIC TRANSMISSION - 44REBR/BE
OVERDRIVE UNIT (Continued)

(3) Remove overrunning clutch assembly with
expanding type snap-ring pliers (Fig. 139). Insert pli-
ers into clutch hub. Expand pliers to grip hub splines
and remove clutch with counterclockwise, twisting
motion.
(4) Remove thrust bearing from overrunning
clutch hub.
(5) Remove overrunning clutch from hub.
(6) Mark position of annulus gear and direct clutch
drum for assembly alignment reference (Fig. 140).
Use small center punch or scriber to make alignment
marks.(7) Remove direct clutch drum rear retaining ring
(Fig. 141).
(8) Remove direct clutch drum outer retaining ring
(Fig. 142).
Fig. 141 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
2 - DIRECT CLUTCH DRUM
3 - ANNULUS GEAR
Fig. 142 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 139 Overrunning Clutch
1 - OVERRUNNING CLUTCH
2 - NEEDLE BEARING
Fig. 140 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 - DIRECT CLUTCH DRUM
2 - HAMMER
3 - PUNCH
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 393
OVERDRIVE UNIT (Continued)

(9) Mark annulus gear and output shaft for assem-
bly alignment reference (Fig. 143). Use punch or
scriber to mark gear and shaft.
(10) Remove snap-ring that secures annulus gear
on output shaft (Fig. 144). Use two screwdrivers to
unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig.
145). Use rawhide or plastic mallet to tap gear off
shaft.
GEAR CASE AND PARK LOCK
(1) Remove locating ring from gear case.
(2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap-ring and remove
reaction plug.
(4) Remove output shaft seal.
CLEANING
Clean the geartrain and case components with sol-
vent. Dry all parts except the bearings with com-
pressed air. Allow bearings to air dry.
Do not use shop towels for wiping parts dry unless
the towels are made from a lint-free material. A suf-
ficient quantity of lint (from shop towels, cloths, rags,
etc.) could plug the transmission filter and fluid pas-
sages.
Discard the old case gasket and seals. Do not
attempt to salvage these parts. They are not reus-
able. Replace any of the overdrive unit snap-rings if
distorted or damaged.
Minor nicks or scratches on components can be
smoothed with crocus cloth. However, do not attempt
to reduce severe scoring on any components with
abrasive materials. Replace severely scored compo-
nents; do not try to salvage them.
INSPECTION
Check condition of the park lock components and
the overdrive case.
Check the bushings in the overdrive case. Replace
the bushings if severely scored or worn. Also replace
the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and
plates. Replace the discs if the facing is worn,
severely scored, or burned and flaking off. Replace
Fig. 143 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
Fig. 144 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 145 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
21 - 394 AUTOMATIC TRANSMISSION - 44REBR/BE
OVERDRIVE UNIT (Continued)

the clutch plates if worn, heavily scored, or cracked.
Check the lugs on the clutch plates for wear. The
plates should slide freely in the drum. Replace the
plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch
hub, clutch drum and clutch spring. Replace the gear,
hub and drum if worn or damaged. Replace the
spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and
hub are in good condition. The clutch plates and
discs should slide freely in these components.
Inspect the thrust bearings and spring plate.
Replace the plate if worn or scored. Replace the bear-
ings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun
gear and bushings. If either the sun gear or the
bushings are damaged, replace the gear and bush-
ings as an assembly. The gear and bushings are not
serviced separately.
The planetary carrier and pinions must be in good
condition. Also be sure the pinion pins are secure and
in good condition. Replace the carrier if worn or dam-
aged.
Inspect the overrunning clutch and race. The race
surface should be smooth and free of scores. Replace
the overrunning clutch assembly or the race if either
assembly is worn or damaged in any way.
Replace the shaft pilot bushing and inner bushing
if damaged. Replace either shaft bearing if rough or
noisy. Replace the bearing snap-rings if distorted or
cracked.
Check the machined surfaces on the output shaft.
These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Inspect the output shaft bushings. The small bush-
ing is the intermediate shaft pilot bushing. The large
bushing is the overrunning clutch hub bushing.
Replace either bushing if scored, pitted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak direct clutch and overdrive clutch discs in
MopartATF +4, type 9602, transmission fluid. Allow
discs to soak for 10-20 minutes.
(2) Install new pilot bushing and clutch hub bush-
ing in output shaft if necessary (Fig. 146). Lubricate
bushings with petroleum jelly, or transmission fluid.
(3) Install annulus gear on output shaft, if
removed. Then install annulus gear retaining snap-
ring (Fig. 147).
Fig. 146 Output Shaft Pilot Bushing
1 - OUTPUT SHAFT HUB
2 - OVERRUNNING CLUTCH HUB BUSHING
3 - INTERMEDIATE SHAFT PILOT BUSHING
Fig. 147 Annulus Gear Installation
1 - SNAP-RING
2 - OUTPUT SHAFT FRONT BEARING
3 - ANNULUS GEAR
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 395
OVERDRIVE UNIT (Continued)