ECU DODGE RAM 2001 Service Repair Manual

DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Disconnect wires from governor pressure sen-
sor and solenoid.
(2) Remove screws attaching governor body and
retainer plate to transfer plate.
(3) Remove retainer plate, governor body and gas-
ket from transfer plate.
(4) Remove governor pressure sensor from gover-
nor body.
(5) Remove governor pressure solenoid by pulling
it straight out of bore in governor body. Remove and
discard solenoid O-rings if worn, cut, or torn.
(6) Remove small shoulder bolt that secures sole-
noid harness case connector to 3-4 accumulator hous-
ing (Fig. 268). Retain shoulder bolt. Either tape it to
harness or thread it back into accumulator housing
after connector removal.
(7) Unhook overdrive/converter solenoid harness
from 3-4 accumulator cover plate (Fig. 269).
(8) Turn valve body over and remove screws that
attach overdrive/converter solenoid assembly to valve
body (Fig. 270).
(9) Remove solenoid and harness assembly from
valve body (Fig. 271).
(10) Remove boost valve cover (Fig. 272).
(11) Remove boost valve retainer, valve spring and
boost valve (Fig. 273).
Fig. 268 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
2 - 3-4 ACCUMULATOR HOUSING
Fig. 269 Unhooking Solenoid Harness From
Accumulator Cover Plate
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 453
VALVE BODY (Continued)

(12) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 274).
(13) Remove park rod E-clip and separate rod from
manual lever (Fig. 275).
(14) Remove E-clip and washer that retains throt-
tle lever shaft in manual lever (Fig. 276).
(15) Remove manual lever and throttle lever (Fig.
277). Rotate and lift manual lever off valve body and
throttle lever shaft. Then slide throttle lever out of
valve body.
(16) Position pencil magnet next to detent housing
to catch detent ball and spring. Then carefully
remove Retainer Tool 6583 and remove detent ball
and spring (Fig. 278).
(17) Remove screws attaching pressure adjusting
screw bracket to valve body and transfer plate (Fig.
279). Hold bracket firmly against spring tension
while removing last screw.
Fig. 274 Detent Ball And Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 275 Park Rod
1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD
Fig. 276 Throttle Lever E-Clip And Washer
1 - THROTTLE LEVER SHAFT
2 - E-CLIP AND WASHER
3 - MANUAL SHAFT
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 455
VALVE BODY (Continued)

VALVE BODY UPPER HOUSING
(1) Note location of check balls in valve body upper
housing (Fig. 292). Then remove the one large diam-
eter and the six smaller diameter check balls.
(2) Remove governor plug and shuttle valve covers
(Fig. 294).
(3) Remove E-clip that secures shuttle valve sec-
ondary spring on valve stem (Fig. 293).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 294).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
(6) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 281).
(7) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 295).
(8) Remove limit valve housing. Then remove
retainer, spring, limit valve, and 2-3 throttle plug
from limit valve housing (Fig. 295).
(9) Remove 1-2 shift control valve and spring (Fig.
295).
(10) Remove 1-2 shift valve and spring (Fig. 295).
(11) Remove 2-3 shift valve and spring from valve
body (Fig. 295).
(12) Remove pressure plug cover (Fig. 295).
(13) Remove line pressure plug, sleeve, throttle
pressure plug and spring (Fig. 295).
Fig. 289 Transfer Plate
1 - UPPER HOUSING
2 - TRANSFER PLATE
Fig. 290 Upper Housing Separator Plate
1 - TRANSFER PLATE
2 - UPPER HOUSING SEPARATOR PLATE
3 - FILTER SCREEN
4 - BRACE
Fig. 291 Rear Clutch And Rear Servo Check Ball
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
21 - 460 AUTOMATIC TRANSMISSION - 44REBR/BE
VALVE BODY (Continued)

BOOST VALVE TUBE AND BRACE
(1) Position valve body assembly so lower housing
is facing upward (Fig. 308).
(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 308).
(4) Insert and seat each end of tube in housings.
(5) Slide tube brace under tube and into alignment
with valve body screw holes (Fig. 309).
(6) Install and finger tighten three screws that
secure tube brace to valve body housings (Fig. 309).
(7) Bend tube brace tabs up and against tube to
hold it in position (Fig. 310).
(8) Tighten all valve body housing screws to 4 N´m
(35 in. lbs.) torque after tube and brace are installed.
Tighten screws in diagonal pattern starting at center
and working outward.
3-4 ACCUMULATOR
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 311).
(2) Loosely attach accumulator housing with right-
side screw (Fig. 311). Install only one screw at this
time as accumulator must be free to pivot upward for
ease of installation.
(3) Install 3-4 shift valve and spring.
(4) Install converter clutch timing valve and
spring.(5) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(6) Swing accumulator housing upward over valve
springs and plug.
(7) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated
(Fig. 312). Tighten screws to 4 N´m (35 in. lbs.).
Fig. 308 Boost Valve Tube
1 - BOOST VALVE TUBE
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 309 Boost Valve Tube And Brace
1 - BOOST VALVE TUBE
2 - TUBE BRACE
Fig. 310 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
21 - 472 AUTOMATIC TRANSMISSION - 44REBR/BE
VALVE BODY (Continued)

Test Four - Transmission In Reverse
NOTE: This test checks pump output, pressure reg-
ulation and the front clutch and rear servo circuits.
Use 300 psi Test Gauge C-3293-SP for this test.
(1) Leave vehicle on hoist and leave gauge C-3292
in place at accumulator port.
(2) Move 300 psi Gauge C-3293-SP back to rear
servo port.
(3) Have helper start and run engine at 1600 rpm
for test.
(4) Move transmission shift lever four detents
rearward from full forward position. This is Reverse
range.
(5) Move transmission throttle lever fully forward
then fully rearward and note reading at Gauge
C-3293-SP.
(6) Pressure should be 145 - 175 psi (1000-1207
kPa) with throttle lever forward and increase to 230 -
280 psi (1586-1931 kPa) as lever is gradually moved
rearward.
Test Five - Governor Pressure
NOTE: This test checks governor operation by mea-
suring governor pressure response to changes in
vehicle speed. It is usually not necessary to check
governor operation unless shift speeds are incor-
rect or if the transmission will not downshift. The
test should be performed on the road or on a hoist
that will allow the rear wheels to rotate freely.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(2) Move transmission shift lever two detents rear-
ward from full forward position. This is D range.
(3) Have helper start and run engine at curb idle
speed. Then firmly apply service brakes so wheels
will not rotate.
(4) Note governor pressure:
²Governor pressure should be no more than 20.6
kPa (3 psi) at curb idle speed and wheels not rotat-
ing.²If pressure exceeds 20.6 kPa (3 psi), a fault
exists in governor pressure control system.
(5) Release brakes, slowly increase engine speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pres-
sure should increase in proportion to vehicle speed.
Or approximately 6.89 kPa (1 psi) for every 1 mph.
(6) Governor pressure rise should be smooth and
drop back to no more than 20.6 kPa (3 psi), after
engine returns to curb idle and brakes are applied to
prevent wheels from rotating.
(7) Compare results of pressure test with analysis
chart.
Test Six - Transmission In Overdrive Fourth Gear
NOTE: This test checks line pressure at the over-
drive clutch in fourth gear range. Use 300 psi Test
Gauge C-3293-SP for this test. The test should be
performed on the road or on a chassis dyno.
(1) Remove tachometer; it is not needed for this
test.
(2) Move 300 psi Gauge to overdrive clutch pres-
sure test port. Then remove other gauge and reinstall
test port plug.
(3) Lower vehicle.
(4) Turn OD switch on.
(5) Secure test gauge so it can be viewed from
drivers seat.
(6) Start engine and shift into D range.
(7) Increase vehicle speed gradually until 3-4 shift
occurs and note gauge pressure.
(8) Pressure should be 469-496 kPa (68-72 psi)
with closed throttle and increase to 620-827 kPa (90-
120 psi) at 1/2 to 3/4 throttle. Note that pressure can
increase to around 896 kPa (130 psi) at full throttle.
(9) Return to shop or move vehicle off chassis
dyno.
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 489
AUTOMATIC TRANSMISSION - 46RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3
SHIFT1. Overdrive Solenoid Connector or
Wiring Shorted.1. Test connector and wiring for loose
connections, shorts or ground and repair as
needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary.
Check with DRBTscan tool.
3. PCM Malfunction. 3. Test PCM with DRBTscan tool and
replace controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect
valve body components. Make sure all
valves and plugs slide freely in bores.
Polish valves with crocus cloth if needed.
WHINE/NOISE RELATED
TO ENGINE SPEED1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.4. Check with DRBTscan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRBTscan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
7. PCM Malfunction. 7. Check with DRBTscan tool and replace
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRBTscan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 499
AUTOMATIC TRANSMISSION - 46RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
SLIPS IN OVERDRIVE
FOURTH GEAR1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild clutch
pack.
3. Overdrive Piston Retainer Bleed
Orifice Blown Out.3. Disassemble transmission, remove
retainer and replace orifice.
4. Overdrive Piston or Seal
Malfunction.4. Remove overdrive unit. Replace seals if
worn. Replace piston if damaged. If piston
retainer is damaged, remove and
disassemble the transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.5. Remove and overhaul valve body.
Replace accumulator seals. Make sure all
valves operate freely in bores and do not
bind or stick. Make sure valve body screws
are correctly tightened and separator plates
are properly positioned.
6. Overdrive Unit Thrust Bearing
Failure.6. Disassemble overdrive unit and replace
thrust bearing (NO. 1 thrust bearing is
between overdrive piston and clutch hub;
NO. 2 thrust bearing is between the
planetary gear and the direct clutch spring
plate; NO. 3 thrust bearing is between
overrunning clutch hub and output shaft).
7. O/D Check Valve/Bleed Orifice
Failure.7. Check for function/secure orifice insert in
O/D piston retainer.
DELAYED 3-4 UPSHIFT
(SLOW TO ENGAGE)1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Throttle Valve Cable Mis-adjusted. 2. Adjust throttle valve cable.
3. Overdrive Clutch Pack Worn/
Burnt.3. Remove unit and rebuild clutch pack.
4. TPS Faulty. 4. Test with DRBTscan tool and replace as
necessary
5. Overdrive Clutch Bleed Orifice
Plugged.5. Disassemble transmission and replace
orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.6. Test solenoid and check wiring for
loose/corroded connections or shorts/
grounds. Replace solenoid if faulty and
repair wiring if necessary.
7. Overdrive Excess Clearance. 7. Remove unit. Measure end play and
select proper spacer.
8. O/D Check Valve Missing or
Stuck.8. Check for presence of check valve.
Repair or replace as required.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEARLockup Solenoid, Relay or Wiring
Shorted/Open.Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2, 2-3, 3-4 OR
3-2 SHIFTSLockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
21 - 500 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)

(12) Disconnect wires from park/neutral position
switch and transmission solenoid.
(13) Disconnect gearshift rod and torque shaft
assembly from transmission.
(14) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever.
(15) On4x4models, disconnect shift rod from
transfer case shift lever.
(16)
Support rear of engine with safety stand or jack.
(17) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(18) Remove bolts securing rear support and cush-
ion to transmission and crossmember. Raise trans-
mission slightly, slide exhaust hanger arm from
bracket (Fig. 15) and remove rear support.(19) Remove bolts attaching crossmember to frame
and remove crossmember.
(20) On4x4models, remove transfer case with
transmission jack or aid of helper.
(21) Remove all converter housing bolts.
(22) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(23) Lower transmission and remove assembly
from under the vehicle.
(24) To remove torque converter, remove C-clamp
from edge of bell housing and carefully slide torque
converter out of the transmission.
DISASSEMBLY
(1) Clean exterior of transmission with suitable
solvent or pressure washer.
(2) Place transmission in vertical position.
(3) Measure the input shaft end play as follows
(Fig. 16).
(a) Attach Adapter 8266-5 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c)
Install the assembled tool onto the input shaft
of the transmission and tighten the retaining screw
on Adapter 8266-5 to secure it to the input shaft.
(d)Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indicator.
(e)Move input shaft in and out and record read-
ing. Record the maximum travel for assembly refer-
ence
Fig. 14 Fill Tube Attachment
1 - TRANSFER CASE VENT TUBE
2 - FILL TUBE (V8)
3 - TUBE SEAL
4 - FILL TUBE (V6)
Fig. 15 Rear Support Cushion
1 - EXHAUST PIPE ARM AND BRACKET
2 - CROSSMEMBER
3 - REAR SUPPORT AND CUSHION
Fig. 16 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 503
AUTOMATIC TRANSMISSION - 46RE (Continued)

(4) Install thrust washer in low-reverse drum spot-
face (Fig. 48). Use petroleum jelly to hold washer in
place.
(5) Install snap-ring that secures low-reverse drum
to piston retainer hub (Fig. 48).
(6) Insert band reaction pin part way into case and
band link (Fig. 49).
(7) Install rear band adjusting lever, reaction lever,
and strut (Fig. 50). Be sure levers and strut are
aligned and engaged before seating band reaction pin
in case.
PLANETARY GEARTRAIN, FRONT/REAR CLUTCH,
AND FRONT BAND
(1) Remove Alignment Shaft 6227-2, if installed
previously.
(2)
Install assembled intermediate shaft and plane-
tary geartrain (Fig. 51).Support shaft carefully dur-
ing installation. Do not allow shaft bearing/
bushing surfaces to become nicked or scratched.
Fig. 51 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN
ASSEMBLY
Fig. 48 Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - TABBED WASHER
3 - SNAP-RING
Fig. 49 Rear Band Reaction Pin
1 - REACTION PIN
2 - BAND LINK
3 - REAR BAND
4 - O-RINGS
Fig. 50 Rear Band Levers And Strut
1 - ADJUSTING SCREW AND NUT
2 - ADJUSTING LEVER
3 - REACTION LEVER
4 - STRUT
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 513
AUTOMATIC TRANSMISSION - 46RE (Continued)

INPUT SHAFT END PLAY CHECK
NOTE: Overdrive unit must be installed in order to
correctly measure the input shaft end-play.
(1) Measure input shaft end play (Fig. 62).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or reaction shaft thrust
washer is incorrect. The reaction shaft thrust
washer is selective.
(a) Attach Adapter 8266-5 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-5 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. End play should be 0.86-2.13 mm (0.034-0.084
in.). Adjust as necessary.
ACCUMULATOR, VALVE BODY, OIL PAN, AND
TORQUE CONVERTER
(1) Install accumulator inner spring, piston and
outer spring (Fig. 63).(2) Verify that park/neutral position switch has
notbeen installed in case. Valve body can not be
installed if switch is in position.
(3) Install new valve body manual shaft seal in
case (Fig. 64). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
(4) Install valve body as follows:
(a) Start park rod into park pawl. If rod will not
slide past park pawl, pawl is engaged in park gear.
Rotate overdrive output shaft with suitable size 12
point socket; this will free pawl and allow rod to
engage.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a diag-
onal pattern to 12 N´m (105 in. lbs.) torque.Do
not overtighten valve body bolts. This could
result in distortion and cross leakage after
installation..
(5) Install new filter on valve body. Tighten filter
screws to 4 N´m (35 in. lbs.).
(6) Install seal on park/neutral position switch.
Then install and tighten switch to 34 N´m (25 ft.
lbs.).
Fig. 61 Oil Pump
1 - SEAT OIL PUMP IN CASE BY HAND
2 - REMOVE PILOT STUDS WHEN PUMP IS SEATED
Fig. 62 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 517
AUTOMATIC TRANSMISSION - 46RE (Continued)