automatic transmission DODGE RAM 2001 Service Repair Manual

Fig. 305 Shuttle And Boost Valve Components
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 469
VALVE BODY (Continued)

Fig. 306 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
21 - 470 AUTOMATIC TRANSMISSION - 44REBR/BE
VALVE BODY (Continued)

Fig. 307 Upper Housing Shift Valve And Pressure Plug Locations
1 - UPPER HOUSING 8 - RETAINER
2 - 1-2 SHIFT VALVE AND SPRING 9 - 1-2 SHIFT CONTROL VALVE AND SPRING
3 - 2-3 SHIFT VALVE AND SPRING 10 - PRESSURE PLUG COVER
4 - 2-3 THROTTLE PLUG 11 - LINE PRESSURE PLUG
5 - LIMIT VALVE HOUSING 12 - PLUG SLEEVE
6 - LIMIT VALVE COVER 13 - THROTTLE PRESSURE SPRING AND PLUG
7 - LIMIT VALVE AND SPRING
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 471
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)

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)

GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn valve body assembly over so accumulator
side of transfer plate is facing down.
(2) Install new O-rings on governor pressure sole-
noid and sensor.
(3) Lubricate solenoid and sensor O-rings with
clean transmission fluid.
(4) Install governor pressure sensor in governor
body.
(5) Install governor pressure solenoid in governor
body. Push solenoid in until it snaps into place in
body.
(6) Position governor body gasket on transfer
plate.(7) Install retainer plate on governor body and
around solenoid. Be sure solenoid connector is posi-
tioned in retainer cutout.
(8) Align screw holes in governor body and trans-
fer plate. Then install and tighten governor body
screws to 4 N´m (35 in. lbs.) torque.
(9) Connect harness wires to governor pressure
solenoid and governor pressure sensor.
(10) Install fluid filter and pan.
(11) Lower vehicle.
(12) Fill transmission with recommended fluid and
road test vehicle to verify repair.
Fig. 313 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 314 Manual And Throttle Lever Alignment
1 - THROTTLE LEVER
2 - MANUAL LEVER VALVE ARM
3 - MANUAL VALVE
4 - KICKDOWN VALVE
Fig. 315 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
2 - 3-4 ACCUMULATOR HOUSING
Fig. 316 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
21 - 474 AUTOMATIC TRANSMISSION - 44REBR/BE
VALVE BODY (Continued)

INSTALLATION
(1) Check condition of O-ring seals on valve body
harness connector (Fig. 317). Replace seals on con-
nector body if cut or worn.
(2) Check condition of manual lever shaft seal in
transmission case. Replace seal if lip is cut or worn.
Install new seal with 15/16 deep well socket (Fig.
318).
(3) Check condition of seals on accumulator piston
(Fig. 319). Install new piston seals, if necessary.
(4) Place valve body manual lever in low (1 posi-
tion) so ball on park lock rod will be easier to install
in sprag.
(5) Lubricate shaft of manual lever with petroleum
jelly. This will ease inserting shaft through seal in
case.
(6) Lubricate seal rings on valve body harness con-
nector with petroleum jelly.
(7) Position valve body in case and work end of
park lock rod into and through pawl sprag. Turn pro-
peller shaft to align sprag and park lock teeth if nec-
essary. The rod will click as it enters pawl. Move rod
to check engagement.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.
(8) Install accumulator springs and piston into
case. Then swing valve body over piston and outer
spring to hold it in place.
(9) Align accumulator piston and outer spring,
manual lever shaft and electrical connector in case.
(10) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(11) Tighten valve body bolts alternately and
evenly to 11 N´m (100 in. lbs.) torque.
(12) Install new fluid filter on valve body. Tighten
filter screws to 4 N´m (35 in. lbs.) torque.
(13) Install throttle and gearshift levers on valve
body manual lever shaft.
(14) Check and adjust front and rear bands if nec-
essary.
(15) Connect solenoid case connector wires.
(16) Install oil pan and new gasket. Tighten pan
bolts to 17 N´m (13 ft. lbs.) torque.
(17) Lower vehicle and fill transmission with
MopartATF +4, type 9602, fluid.
(18) Check and adjust gearshift and throttle valve
cables, if necessary.
Fig. 317 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
Fig. 318 Manual Lever Shaft Seal
1 - 15/16©© SOCKET
2 - SEAL
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 475
VALVE BODY (Continued)

ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body;
²Line Pressure
²Throttle Pressure
Line and throttle pressures are interdependent
because each affects shift quality and timing. As a
result, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
LINE PRESSURE ADJUSTMENT
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 320).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa).
Turning the adjusting screw counterclockwise
increases pressure while turning the screw clockwise
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
Insert Gauge Tool C-3763 between the throttle
lever cam and the kickdown valve stem (Fig. 321).
Push the gauge tool inward to compress the kick-
down valve against the spring and bottom the throt-
tle valve.Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until the screw head
touches throttle lever tang and the throttle lever cam
touches gauge tool.
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 319 Accumulator Piston Components
1 - INNER SPRING
2 - ACCUMULATOR PISTON
3 - OUTER SPRING
4 - SEAL RINGS
Fig. 320 Line Pressure Adjustment
1 - WRENCH
2 - 1±5/16 INCH
Fig. 321 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
21 - 476 AUTOMATIC TRANSMISSION - 44REBR/BE
VALVE BODY (Continued)

AUTOMATIC TRANSMISSION - 46RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 46RE
DESCRIPTION..........................478
OPERATION............................480
DIAGNOSIS AND TESTING................486
AUTOMATIC TRANSMISSION.............486
PRELIMINARY........................486
ROAD TESTING.......................486
HYDRAULIC PRESSURE TEST...........487
AIR TESTING TRANSMISSION CLUTCH
AND BAND OPERATION.................490
CONVERTER HOUSING FLUID LEAK......491
DIAGNOSIS CHARTS...................492
STANDARD PROCEDURE.................502
ALUMINUM THREAD REPAIR.............502
REMOVAL.............................502
DISASSEMBLY..........................503
CLEANING.............................509
INSPECTION...........................510
ASSEMBLY............................510
INSTALLATION..........................518
SCHEMATICS AND DIAGRAMS.............520
SPECIFICATIONS........................532
SPECIAL TOOLS........................534
ACCUMULATOR
DESCRIPTION..........................537
OPERATION............................537
INSPECTION...........................538
BANDS
DESCRIPTION..........................538
OPERATION............................539
ADJUSTMENTS.........................539
ELECTRONIC GOVERNOR
DESCRIPTION..........................540
OPERATION............................541
REMOVAL.............................542
INSTALLATION..........................543
EXTENSION HOUSING BUSHING
REMOVAL.............................544
INSTALLATION..........................544
EXTENSION HOUSING SEAL
REMOVAL.............................544
INSTALLATION..........................544
FLUID AND FILTER
DIAGNOSIS AND TESTING................545
EFFECTS OF INCORRECT FLUID LEVEL . . . 545
CAUSES OF BURNT FLUID..............545
FLUID CONTAMINATION................545
STANDARD PROCEDURE.................545
FLUID LEVEL CHECK...................545FLUID AND FILTER REPLACEMENT.......547
TRANSMISSION FILL...................547
FRONT CLUTCH
DESCRIPTION..........................548
OPERATION............................548
DISASSEMBLY..........................549
INSPECTION...........................550
ASSEMBLY............................550
FRONT SERVO
DESCRIPTION..........................551
OPERATION............................552
DISASSEMBLY..........................552
CLEANING.............................552
INSPECTION...........................553
ASSEMBLY............................553
OIL PUMP
DESCRIPTION..........................554
OPERATION............................554
STANDARD PROCEDURE.................554
OIL PUMP VOLUME CHECK..............554
DISASSEMBLY..........................555
CLEANING.............................557
INSPECTION...........................557
ASSEMBLY............................558
OUTPUT SHAFT FRONT BEARING
REMOVAL.............................559
INSTALLATION..........................560
OUTPUT SHAFT REAR BEARING
REMOVAL.............................560
INSTALLATION..........................560
OVERDRIVE CLUTCH
DESCRIPTION..........................560
OPERATION............................560
OVERDRIVE UNIT
REMOVAL.............................560
DISASSEMBLY..........................562
CLEANING.............................568
INSPECTION...........................569
ASSEMBLY............................569
INSTALLATION..........................577
OVERDRIVE SWITCH
DESCRIPTION..........................578
OPERATION............................579
DIAGNOSIS AND TESTING................579
OVERDRIVE ELECTRICAL CONTROLS.....579
REMOVAL.............................579
INSTALLATION..........................579
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 477

OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION..........................580
OPERATION............................580
DISASSEMBLY..........................580
CLEANING.............................580
INSPECTION...........................580
ASSEMBLY............................581
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING................583
PARK/NEUTRAL POSITION SWITCH.......583
REMOVAL.............................583
INSTALLATION..........................583
PISTONS
DESCRIPTION..........................584
OPERATION............................584
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION..........................585
OPERATION............................585
DISASSEMBLY..........................586
INSPECTION...........................587
ASSEMBLY............................588
REAR CLUTCH
DESCRIPTION..........................591
OPERATION............................592
DISASSEMBLY..........................592
CLEANING.............................593
INSPECTION...........................593
ASSEMBLY............................593
REAR SERVO
DESCRIPTION..........................594
OPERATION............................594
DISASSEMBLY..........................594
CLEANING.............................594
ASSEMBLY............................595
SHIFT MECHANISM
DESCRIPTION..........................595OPERATION............................595
ADJUSTMENTS.........................596
SOLENOID
DESCRIPTION..........................596
OPERATION............................597
SPEED SENSOR
DESCRIPTION..........................597
OPERATION............................597
THROTTLE VALVE CABLE
DESCRIPTION..........................597
ADJUSTMENTS.........................598
TORQUE CONVERTER
DESCRIPTION..........................600
OPERATION............................604
REMOVAL.............................605
INSTALLATION..........................605
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION..........................605
OPERATION............................605
STANDARD PROCEDURE.................606
TORQUE CONVERTER DRAINBACK VALVE . 606
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION..........................606
OPERATION............................606
VALVE BODY
DESCRIPTION..........................607
OPERATION............................611
REMOVAL.............................625
DISASSEMBLY..........................626
CLEANING.............................637
INSPECTION...........................637
ASSEMBLY............................638
INSTALLATION..........................645
ADJUSTMENTS.........................646
AUTOMATIC TRANSMISSION -
46RE
DESCRIPTION
The 46RE (Fig. 1) is a four speed fully automatic
transmissions with an electronic governor. The 46RE
is equipped with a lock-up clutch in the torque con-
verter. First through third gear ranges are provided
by the clutches, bands, overrunning clutch, and plan-
etary gear sets in the transmission. Fourth gear
range is provided by the overdrive unit that contains
an overdrive clutch, direct clutch, planetary gear set,
and overrunning clutch.
The transmission contains a front, rear, and direct
clutch which function as the input driving compo-
nents. It also contains the kickdown (front) and thelow/reverse (rear) bands which, along with the over-
running clutch and overdrive clutch, serve as the
holding components. The driving and holding compo-
nents combine to select the necessary planetary gear
components, in the front, rear, or overdrive planetary
gear set, transfer the engine power from the input
shaft through to the output shaft.
The valve body is mounted to the lower side of the
transmission and contains the valves to control pres-
sure regulation, fluid flow control, and clutch/band
application. The oil pump is mounted at the front of
the transmission and is driven by the torque con-
verter hub. The pump supplies the oil pressure nec-
essary for clutch/band actuation and transmission
lubrication.
21 - 478 AUTOMATIC TRANSMISSION - 46REBR/BE