light DODGE RAM 2001 Service Repair Manual

(14) Install assembled sun gear, spring plate and
thrust bearing (Fig. 155). Be sure sun gear and
thrust bearing are fully seated before proceeding.
(15) Mount assembled output shaft, annulus gear,
and clutch drum in shop press. Direct clutch spring,
hub and clutch pack are easier to install with assem-
bly mounted in press.
(16) Align splines in hubs of planetary gear and
overrunning clutch with Alignment tool 6227-2 (Fig.
156). Insert tool through sun gear and into splines of
both hubs. Be sure alignment tool is fully seated
before proceeding.
(17) Install direct clutch spring (Fig. 157). Be sure
spring is properly seated on spring plate.
NOTE: The 44RE transmission has 8 direct clutch
discs and 7 clutch plates.
(18) Assemble and install direct clutch pack on
hub as follows:
(a) Assemble clutch pack components (Fig. 158).
(b) Install direct clutch reaction plate on clutch
hub first. Note that one side of reaction plate is
counterbored. Be sure this side faces rearward.
Splines at rear of hub are raised slightly. Counter-
bore in plate fits over raised splines. Plate should
be flush with this end of hub (Fig. 159).
(c) Install first clutch disc followed by a steel
plate until all discs and plates have been installed.
(d) Install pressure plate. This is last clutch
pack item to be installed. Be sure plate is installed
with shoulder side facing upward (Fig. 160).
(19) Install clutch hub and clutch pack on direct
clutch spring (Fig. 161). Be sure hub is started on
sun gear splines before proceeding.
Fig. 155 Sun Gear Installation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
Fig. 156 Alignment Tool Installation
1 - SPECIAL TOOL 6227-2
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
Fig. 157 Direct Clutch Spring Installation
1 - SPECIAL TOOL 6227-2
2 - DIRECT CLUTCH SPRING
3 - CLUTCH HUB
4 - PRESS PLATES
21 - 398 AUTOMATIC TRANSMISSION - 44REBR/BE
OVERDRIVE UNIT (Continued)

(1) Remove the overdrive piston (Fig. 180).
(2) Remove the overdrive piston retainer bolts.
(3) Remove overdrive piston retainer.
(4) Remove case gasket.
(5) Mark the position of the overrunning clutch
cam in the case (Fig. 181).
(6) Remove the overrunning clutch cam bolts.
(7) Remove the overrunning clutch cam.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
low-reverse drum, and overdrive piston retainer insolvent. Dry them with compressed air after clean-
ing.
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 drum if the clutch race,
roller surface or inside diameter is scored, worn or
damaged.Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Examine the overdrive piston retainer carefully for
wear, cracks, scoring or other damage. Be sure the
retainer hub is a snug fit in the case and drum.
Replace the retainer if worn or damaged.
ASSEMBLY
(1) Examine bolt holes in overrunning clutch cam.
Note that one hole isnot threaded(Fig. 182). This
hole must align with blank area in clutch cam bolt
circle (Fig. 183). Mark hole location on clutch cam
and blank area in case with grease pencil, paint
stripe, or scribe mark for assembly reference.
(2) Mark location of non-threaded hole in clutch
cam and blank area in bolt circle with grease pencil.
(3) Align and install overrunning clutch and cam
in case (Fig. 184). Be sure cam is correctly installed.
Bolt holes in cam are slightly countersunk on one
side. Be sure this side of cam faces rearward (toward
piston retainer).
Fig. 180 Overdrive Piston Removal
1 - OVERDRIVE CLUTCH PISTON
2 - INTERMEDIATE SHAFT
3 - SELECTIVE SPACER
4 - PISTON RETAINER
Fig. 181 Overrunning Clutch Cam Removal
1 - ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
2 - OVERRUNNING CLUTCH ASSEMBLY
Fig. 182 Location Of Non-Threaded Hole In Clutch
Cam
1 - NON-THREADED HOLE
2 - OVERRUNNING CLUTCH CAM
21 - 406 AUTOMATIC TRANSMISSION - 44REBR/BE
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

When pressure is released from the piston, the
spring returns the piston to its fully released position
and disengages the clutch. The release spring also
helps to cushion the application of the clutch assem-
bly. When the clutch is in the process of being
released by the release spring, fluid flows through a
vent and one-way ball-check-valve located in the pis-
ton. The check-valve is needed to eliminate the pos-
sibility of plate drag caused by centrifugal force
acting on the residual fluid trapped in the clutch pis-
ton retainer.
DISASSEMBLY
(1) Remove fiber thrust washer from forward side
of clutch retainer.
(2) Remove input shaft front/rear seal rings.
(3) Remove selective clutch pack snap-ring (Fig.
214).(4) Remove top pressure plate, clutch discs, steel
plates, bottom pressure plate and wave snap-ring
and wave spring (Fig. 214).
(5) Remove clutch piston with rotating motion.
(6) Remove and discard piston seals.
(7) Remove input shaft snap-ring (Fig. 215). It
may be necessary to press the input shaft in slightly
to relieve tension on the snap-ring
(8) Press input shaft out of retainer with shop
press and suitable size press tool. Use a suitably
sized press tool to support the retainer as close to the
input shaft as possible.CLEANING
Clean the clutch components with solvent and dry
them with compressed air. Do not use rags or shop
towels to dry any of the clutch parts. Lint from such
materials will adhere to component surfaces and
could restrict or block fluid passages after assembly.
Fig. 214 Rear Clutch Components
1 - PISTON SPRING 10 - TOP PRESSURE PLATE
2 - REAR CLUTCH PISTON 11 - CLUTCH DISCS (4)
3 - CLUTCH PISTON SEALS 12 - BOTTOM PRESSURE PLATE
4 - OUTPUT SHAFT THRUST WASHER (METAL) 13 - WAVE SPRING
5 - INPUT SHAFT SNAP-RING 14 - CLUTCH PLATES (3)
6 - REAR CLUTCH RETAINER 15 - RETAINER SEAL RING
7 - INPUT SHAFT 16 - SHAFT REAR SEAL RING (PLASTIC)
8 - REAR CLUTCH THRUST WASHER (FIBER) 17 - SHAFT FRONT SEAL RING (TEFLON)
9 - CLUTCH PACK SNAP-RING (SELECTIVE)
21 - 418 AUTOMATIC TRANSMISSION - 44REBR/BE
REAR CLUTCH (Continued)

INSPECTION
Replace the clutch discs if warped, worn, scored,
burned/charred, the lugs are damaged, or if the fac-
ing is flaking off. Replace the top and bottom pres-
sure plates if scored, warped, or cracked. Be sure the
driving lugs on the pressure and clutch plates are
also in good condition. The lugs must not be bent,
cracked or damaged in any way.
Replace the piston spring and wave spring if either
part is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The
clutch and pressure plates should slide freely in the
slots. Replace the retainer if the grooves are worn or
damaged. Also check action of the check balls in the
retainer and piston. Each check ball must move
freely and not stick.
Replace the retainer bushing if worn, scored, or
doubt exists about bushing condition.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.
Check condition of the fiber thrust washer and
metal output shaft thrust washer. Replace either
washer if worn or damaged.
Check condition of the seal rings on the input shaft
and clutch retainer hub. Replace the seal rings only
if worn, distorted, or damaged. The input shaft front
seal ring is teflon with chamfered ends. The rear ring
is metal with interlocking ends.
Check the input shaft for wear, or damage. Replace
the shaft if worn, scored or damaged in any way.
ASSEMBLY
(1) Soak clutch discs in transmission fluid while
assembling other clutch parts.
(2) Install new seal rings on clutch retainer hub
and input shaft, if necessary, (Fig. 216) and (Fig.
217).
(a) Be sure clutch hub seal ring is fully seated in
groove and is not twisted.
(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then press input
shaft into retainer (Fig. 218). Use a suitably sized
press tool to support retainer as close to input shaft
as possible.
(4) Install input shaft snap-ring (Fig. 217).
(5) Invert retainer and press input shaft in oppo-
site direction until snap-ring is seated.
(6) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
(7) Lubricate lip of piston seals with generous
quantity of MopartDoor Ease. Then lubricate
retainer hub and bore with light coat of transmission
fluid.
(8) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.0209thick), can be used to
guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) Install piston spring in retainer and on top of
piston (Fig. 219). Concave side of spring faces down-
ward (toward piston).
(10) Install wave spring in retainer (Fig. 219). Be
sure spring is completely seated in retainer groove.
(11) Install bottom pressure plate (Fig. 216).
Ridged side of plate faces downward (toward piston)
and flat side toward clutch pack.
(12) Install first clutch disc in retainer on top of
bottom pressure plate. Then install a clutch plate fol-
lowed by a clutch disc until entire clutch pack is
installed (4 discs and 3 plates are required) (Fig.
216).
(13) Install top pressure plate.
(14) Install selective snap-ring. Be sure snap-ring
is fully seated in retainer groove.
Fig. 215 Removing Input Shaft Snap-Ring
1 - REAR CLUTCH RETAINER
2 - INPUT SHAFT SNAP-RING
3 - SNAP-RING PLIERS
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 419
REAR CLUTCH (Continued)

Fig. 216 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
1 - REAR CLUTCH RETAINER HUB SEAL RING
2 - INPUT SHAFT SEAL RINGS
Fig. 217 Input Shaft Seal Ring Identification
1 - PLASTIC REAR SEAL RING
2 - TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER
SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)
Fig. 218 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAM
Fig. 219 Piston Spring/Wave Spring Position
1 - REAR CLUTCH RETAINER
2 - PISTON SPRING
3 - WAVE SPRING
4 - CLUTCH PISTON
21 - 420 AUTOMATIC TRANSMISSION - 44REBR/BE
REAR CLUTCH (Continued)

ADJUSTMENT PROCEDURE
(1) Turn ignition switch to OFF position.
(2) Remove air cleaner if necessary.
(3) Disconnect cable end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Verify that transmission throttle lever is in
fully closed position. Then be sure lever on throttle
body is at curb idle position.
(5) Pry the T.V. cable lock (A) into the UP position
(Fig. 231). This will unlock the cable and allow for
readjustment.
(6) Apply just enough tension on the T.V. cable (B)
to remove any slack in the cable.Pulling too tight
will cause the T.V. lever on the transmission to
move out of its idle position, which will result
in an incorrect T.V. cable adjustment.Slide the
sheath of the T.V. cable (D) back and forth until the
centerlines of the T.V. cable end (B) and the throttle
bell crank lever (C) are aligned within one millimeter
(1mm) (Fig. 231).(7) While holding the T.V. cable in the set position
push the T.V. cable lock (A) into the down position
(Fig. 231). This will lock the present T.V. cable
adjustment.
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(8) Reconnect the T.V. cable (B) to the throttle
bellcrank lever (C).
(9) Check cable adjustment. Verify transmission
throttle lever and lever on throttle body move simul-
taneously.
Fig. 230 Throttle Valve Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
2 - THROTTLE VALVE CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT(1OR2)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
Fig. 231 Throttle Valve Cable at Throttle Linkage
1 - THROTTLE LINKAGE
2 - THROTTLE VALVE CABLE LOCKING CLIP
3 - THROTTLE VALVE CABLE
21 - 426 AUTOMATIC TRANSMISSION - 44REBR/BE
THROTTLE VALVE CABLE (Continued)

STATOR
Torque multiplication is achieved by locking the
stator's over-running clutch to its shaft (Fig. 239).
Under stall conditions (the turbine is stationary), the
oil leaving the turbine blades strikes the face of the
stator blades and tries to rotate them in a counter-
clockwise direction. When this happens the overrun-
ning clutch of the stator locks and holds the stator
from rotating. With the stator locked, the oil strikes
the stator blades and is redirected into a ªhelpingº
direction before it enters the impeller. This circula-
tion of oil from impeller to turbine, turbine to stator,
and stator to impeller, can produce a maximum
torque multiplication of about 2.4:1. As the turbine
begins to match the speed of the impeller, the fluid
that was hitting the stator in such as way as to
cause it to lock-up is no longer doing so. In this con-
dition of operation, the stator begins to free wheel
and the converter acts as a fluid coupling.
Fig. 238 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
Fig. 239 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 431
TORQUE CONVERTER (Continued)

CLEANING
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution.
Do not immerse any of the electrical components in
cleaning solution. Clean the governor solenoid and
sensor and the dual solenoid and harness assembly
by wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions.Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Wipe the governor pressure sensor and solenoid
valve with dry, lint free shop towels only. The O-rings
on the sensor and solenoid valve are the only service-
able components. Be sure the vent ports in the sole-
noid valve are open and not blocked by dirt or debris.
Replace the valve and/or sensor only when DRB scan
tool diagnosis indicates this is necessary. Or, if either
part has sustained physical damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of
the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
INSPECTION
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-
face. If distortion is severe or any surfaces are
heavily scored, the valve body will have to be
replaced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth
butdo not round off the edges of the valve or
plug lands.Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Fig. 297 Accumulator Housing Components
1 - ACCUMULATOR PISTON
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 465
VALVE BODY (Continued)

VALVE BODY FINAL
(1) Install boost valve, valve spring, retainer and
cover plate. Tighten cover plate screws to 4 N´m (35
in. lbs.) torque.
(2) Insert manual lever detent spring in upper
housing.(3) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with
Retainer Tool 6583 (Fig. 313).
(4) Install throttle lever in upper housing. Then
install manual lever over throttle lever and start
manual lever into housing.
(5) Align manual lever with detent ball and man-
ual valve. Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove
detent ball retainer tool after lever is seated.
(6) Then install manual lever seal, washer and
E-clip.
(7) Verify that throttle lever is aligned with end of
kickdown valve stem and that manual lever arm is
engaged in manual valve (Fig. 314).
(8) Position line pressure adjusting screw in
adjusting screw bracket.
(9) Install spring on end of line pressure regulator
valve.
(10) Install switch valve spring on tang at end of
adjusting screw bracket.
(11) Install manual valve.
(12) Install throttle valve and spring.
(13) Install kickdown valve and detent.
(14) Install pressure regulator valve.
(15) Install switch valve.
(16) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and
long bottom screw last. Verify that valve springs and
bracket are properly aligned. Then tighten all three
bracket screws to 4 N´m (35 in. lbs.) torque.
(17) Perform Line Pressure and Throttle Pressure
adjustments. (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/AUTOMATIC/VALVE BODY - ADJUST-
MENTS)
(18) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly.
(19) Attach solenoid case connector to 3-4 accumu-
lator with shoulder-type screw. Connector has small
locating tang that fits in dimple at top of accumula-
tor housing (Fig. 315). Seat tang in dimple before
tightening connector screw.
(20) Install solenoid assembly and gasket. Tighten
solenoid attaching screws to 8 N´m (72 in. lbs.)
torque.
(21) Verify that solenoid wire harness is properly
routed (Fig. 316). Solenoid harness must be clear of
manual lever and park rod and not be pinched
between accumulator housing and cover.
Fig. 311 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
3 - 3-4 SHIFT VALVE SPRING
4 - CONVERTER CLUTCH VALVE SPRING
Fig. 312 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 473
VALVE BODY (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)