Valve DODGE RAM 2001 Service Repair Manual

(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.
INSTALLATION
(1) Check condition of O-ring seals on valve body
harness connector (Fig. 314). 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.
315).
(3) Check condition of seals on accumulator piston
(Fig. 316). 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.
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.
Fig. 313 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
Fig. 314 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
21 - 818 AUTOMATIC TRANSMISSION - 47REBR/BE
VALVE BODY (Continued)

LINE PRESSURE ADJUSTMENT
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 317).
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. 318).
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. 315 Manual Lever Shaft Seal
1 - 15/16©© SOCKET
2 - SEAL
Fig. 316 Accumulator Piston Components
1 - INNER SPRING
2 - ACCUMULATOR PISTON
3 - OUTER SPRING
4 - SEAL RINGS
Fig. 317 Line Pressure Adjustment
1 - WRENCH
2 - 1±5/16 INCH
Fig. 318 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
BR/BEAUTOMATIC TRANSMISSION - 47RE 21 - 819
VALVE BODY (Continued)

board flange on some non styled base steel wheels.
The tire must be removed to locate the permanent
mark on the inside of the wheel.
Before dismounting a tire from its wheel, a refer-
ence mark should be placed on the tire at the valve
stem location. This reference will ensure that it is
remounted in the original position on the wheel.
(1) Remove the tire and wheel assembly from the
vehicle and mount on a service dynamic balance
machine.
(2) Measure the total runout on the center of the
tire tread rib with a dial indicator. Record the indi-
cator reading. Mark the tire to indicate the high spot.
Place a mark on the tire at the valve stem location
(Fig. 6).
(3) Break down the tire and remount it 180
degrees on the rim (Fig. 7).
(4) Measure the total indicator runout again. Mark
the tire to indicate the high spot.
(5) If runout is still excessive, the following proce-
dures must be done.
²If the high spot is within 101.6 mm (4.0 in.) of
the first spot and is still excessive, replace the tire.
²If the high spot is within 101.6 mm (4.0 in.) of
the first spot on the wheel, the wheel may be out of
specifications. Refer to Wheel and Tire Runout.
²If the high spot is NOT within 101.6 mm (4.0
in.) of either high spot, draw an arrow on the tread
from second high spot to first. Break down the tire
and remount it 90 degrees on rim in that direction
(Fig. 8). This procedure will normally reduce the
runout to an acceptable amount, if not replace the
rim.
Fig. 5 Dual Wheel Tire Rotation Pattern
1 - FRONT
Fig. 6 First Measurement On Tire
1 - REFERENCE MARK
2-1ST MEASUREMENT HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM
Fig. 7 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
BR/BETIRES/WHEELS 22 - 3
TIRES/WHEELS (Continued)

Tire pressures have been chosen to provide safe
operation, vehicle stability, and a smooth ride. Tire
pressure should be checked cold once a month. Tire
pressure decreases as the ambient temperature
drops. Check tire pressure frequently when ambient
temperature varies widely.
Tire inflation pressures are cold inflation pressure.
The vehicle must sit for at least 3 hours to obtain the
correct cold inflation pressure reading. Or be driven
less than one mile after sitting for 3 hours. Tire
inflation pressures may increase from 2 to 6 pounds
per square inch (psi) during operation. Do not reduce
this normal pressure build-up.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A quality air pressure gauge is recommended to
check tire pressure. After checking the air pressure,
replace valve cap finger tight.
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 14).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 15).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 15).
Fig. 12 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 13 Over Inflation Wear
1 - THIN TIRE THREAD AREAFig. 14 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
BR/BETIRES/WHEELS 22 - 7
TIRES (Continued)

SPECIFICATIONS
TIRE REVOLUTIONS PER MILE
TIRE SIZE SUPPLIER REVOLUTIONS PER MILE
P225/75/R16 XL GOODYEAR 716
P245/75R16
WRT/SGOODYEAR 692
P245/75R16
LTX A/SMICHELIN 691
P265/75R16
WRT/SGOODYEAR 668
LT245/75R16 LTX A/S MICHELIN 679
LT245/75R16 LTX M/S MICHELIN 678
LT265/75R16 LTX A/S MICHELIN 648
LT265/75R16 LTX M/S MICHELIN 652
LT275/70R17
WGSAGOODYEAR 650
LT235/85R16
WAPGOODYEAR 650
LT235/85R16
LTX M/SMICHELIN 650
SPARE TIRE
DESCRIPTION
The temporary spare tire is designed for emer-
gency use only. The original tire should be repaired
or replaced at the first opportunity, then reinstalled.
Do not exceed speeds of 50 M.P.H. when using the
temporary spare tire. Refer to Owner's Manual for
complete details.
WHEELS
DESCRIPTION
Original equipment wheels are designed for the
specified Maximum Vehicle Capacity.
All models use steel or cast aluminum drop center
wheels.
Cast aluminum wheels require special balance
weights and alignment equipment.
Ram Truck Models equipped with dual rear wheels
have eight-stud hole rear wheels. The wheels have a
flat mounting surface (Fig. 17). The slots in the
wheel must be aligned to provide access to the valve
stem (Fig. 18).
Fig. 17 Flat Face Wheel
1 - FLAT FACE
BR/BETIRES/WHEELS 22 - 9
TIRES (Continued)

OPERATION
The wheel (Fig. 19) has raised sections between
the rim flanges and the rim well. Initial inflation of
the tire forces the bead over these raised sections. In
case of tire failure, the raised sections hold the tire
in position on the wheel until the vehicle can be
brought to a safe stop.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
²Excessive run out
²Dents or cracks
²Damaged wheel lug nut holes
²Air Leaks from any area or surface of the rim
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
STARDARD PROCEDURE - DUAL REAR WHEEL
INSTALLATION
Dual rear wheels use a special heavy duty lug nut
wrench. It is recommended to remove and install
dual rear wheels only when the proper wrench is
available. The wrench is also use to remove wheel
center caps for more information refer to Owner's
Manual.
The tires on both wheels must be completely raised
off the ground when tightening the lug nuts. This
will ensure correct wheel centering and maximum
wheel clamping.
A two piece flat face lug nut with right-hand
threads is used for retaining the wheels on the hubs
(Fig. 20).
The dual rear wheel lug nuts should be tightened
according to the following procedure:
²Place two drops of oil to the interface of the nut/
washer (Fig. 20) before installing on the wheel stud.
NOTE: Do not use more then two drops of oil on
the nut/washer, since the center caps attach in this
area.
²Tighten the wheel lug nuts in the numbered
sequential pattern until they are snug tight. Then
tighten lug nut to specified torque following same
number sequence, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).
Fig. 18 Dual Rear Wheels
1 - INBOARD WHEEL VALVE STEM
2 - OUTBOARD WHEEL VALVE STEM
Fig. 19 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
22 - 10 TIRES/WHEELSBR/BE
WHEELS (Continued)

STUDS
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper, caliper adapter and
rotor, (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/ROTORS - REMOVAL).
(4) Remove the stud from the hub with Remover
C-4150A (Fig. 21).
INSTALLATION
(1) Install the new stud into the hub flange.
(2) Install the three washers onto the stud, then
install the lug nut with the flat side of the nut
against the washers.
(3) Tighten the lug nut until the stud is pulled
into the hub flange. Verify that the stud is properly
seated into the flange.
(4) Remove the lug nut and washers.
(5) Install the brake rotor, caliper adapter, and cal-
iper, (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/ROTORS - INSTALLATION).
(6) Install the wheel and tire assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE), use new the lug nut on stud or studs that
were replaced.
(7) Remove the support and lower vehicle.
WHEEL COVER
REMOVAL
(1) Insert a hub/cap remover/installer combination
tool around the circumference of the wheel between
the wheel and wheel trim cover.
(2) Twist the tool to remove wheel trim cover.
INSTALLATION - REAR
(1) Install one 1 1/2 in. valve stem extension on
each rear inner wheel.
NOTE: A 3/8 in. drive 10mm deep wheel socket with
a 10 in. or greater extension can be used to remove
the existing valve stem cap and install the exten-
sion.
(2) Install one 1 in. valve stem extension on each
outer wheel.
(3) Align the cooling windows of the wheel skin
with the cooling windows of the wheel. Seat one side
of the wheel skin's retainer onto the wheel. Using a
rubber mallet, strike thew wheel skin on the outer
circumference. Strike at several locations around the
circumference until the skin is fully seated.
NOTE: The wheel skin and the hub cap are fully
seated when there is a consistent gap between the
skin/cap and the wheel.
(4) Tug on the hub/cap wheel skin to ensure that
they are properly installed.
INSTALLATION - FRONT
(1) Align the valve stem with the notch in the
wheel skin.
(2) Seat on side of the wheel skin's wire retainer
on to the wheel.
(3) Using a rubber mallet, strike the opposite side
of the wheel skin until the skin is properly seated.
NOTE: The wheel skin and the hub cap are fully
seated when there is a consistant gap between the
skin/ cap and the wheel.
(4) Tug on the hub cap/wheel skin to ensure that
they are properly installed.
Fig. 21 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
22 - 12 TIRES/WHEELSBR/BE

SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle BR/BE - Ram Pickup
System R134a w/orifice tube
Compressor Sanden SD7H15 SP-20 PAG
oil
Freeze±up
ControlA/C Low Pressure
Switchaccumulator
mounted
Low psi
Controlopens < 22-24 psi
resets > 37-43 psi
High psi
Controlswitch - opens > 450
- 490 psi, resets <
270 - 330 psimounted on
discharge
line, near
compressor
A/C Heater
Control Headmanual type
Mode Door vacuum actuatorItem Description Notes
Blend Door electric actuator
Recirculation
Doorvacuum actuator
Blower Motor hardwired to control
headresistor block
Cooling Fan viscous fan
Clutch
Control relay PCM
Draw 2 - 3.9 amps @ 12V60.5V @
70É F
Gap 0.0169- 0.0319
DRB IIIT
Reads TPS, RPM, A/C
switch test
Actuators clutch relay
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
A/C COMPRESSOR CLUTCH PLATE NUT 14.4 10.5 -
A/C COMPRESOR LINE MANIFOLD
FASTENER22 - 200
A/C COMPRESSOR TO MOUNTING
BRACKET BOLTS24 - 210
ACCUMULATOR RETAINING BAND 4.5 - 40
BLOWER MOTOR SCREWS 2.2 - 20
CHECK VALVE AND NIPPLE UNIT (DIESEL) 24 18 -
CONDENSER MOUNTING SCREWS/NUTS 10.5 - 95
DISCHARGE LINE TO CONDENSER
FASTENER20 - 180
DOOR ACTUATOR SCREWS 2.2 - 20
HVAC HOUSING SCREWS 2.2 - 20
HVAC HOUSING TO DASH PANEL NUTS
(ENGINE SIDE)7-60
HVAC HOUSING TO DASH PANEL NUTS
(PASSENGER COMPARTMENT SIDE)4.5 - 40
24 - 8 HEATING & AIR CONDITIONINGBR/BE
HEATING & AIR CONDITIONING (Continued)

CONTROLS
TABLE OF CONTENTS
page page
CONTROLS
DIAGNOSIS AND TESTING.................10
VACUUM SYSTEM......................10
A/C COMPRESSOR CLUTCH
DESCRIPTION...........................13
OPERATION.............................13
DIAGNOSIS AND TESTING.................13
A/C COMPRESSOR CLUTCH COIL.........13
STANDARD PROCEDURE..................13
A/C COMPRESSOR CLUTCH BREAK-IN.....13
REMOVAL..............................14
INSPECTION............................16
INSTALLATION...........................16
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION...........................17
OPERATION.............................17
DIAGNOSIS AND TESTING.................17
A/C COMPRESSOR CLUTCH RELAY........17
REMOVAL..............................18
INSTALLATION...........................18
A/C HEATER CONTROL
DESCRIPTION...........................18
OPERATION.............................18
DIAGNOSIS AND TESTING.................19
A/C HEATER CONTROL..................19
REMOVAL..............................19
INSTALLATION...........................20
A/C HIGH PRESSURE SWITCH
DESCRIPTION...........................20
OPERATION.............................20
DIAGNOSIS AND TESTING.................20
A/C HIGH PRESSURE SWITCH............20
REMOVAL..............................21
INSTALLATION...........................21
A/C LOW PRESSURE SWITCH
DESCRIPTION...........................21
OPERATION.............................21
DIAGNOSIS AND TESTING.................21
A/C LOW PRESSURE SWITCH............21
REMOVAL..............................21INSTALLATION...........................22
BLOWER MOTOR RELAY
DESCRIPTION...........................22
OPERATION.............................22
DIAGNOSIS AND TESTING.................22
BLOWER MOTOR RELAY.................22
REMOVAL..............................23
INSTALLATION...........................23
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION...........................23
OPERATION.............................23
DIAGNOSIS AND TESTING.................24
BLOWER MOTOR RESISTOR BLOCK.......24
REMOVAL..............................24
INSTALLATION...........................24
BLOWER MOTOR SWITCH
DESCRIPTION...........................24
OPERATION.............................25
DIAGNOSIS AND TESTING.................25
BLOWER MOTOR SWITCH...............25
REMOVAL..............................25
BLEND DOOR ACTUATOR
REMOVAL..............................25
INSTALLATION...........................26
MODE DOOR ACTUATOR
REMOVAL..............................26
INSTALLATION...........................27
RECIRCULATION DOOR ACTUATOR
REMOVAL..............................27
INSTALLATION...........................28
VACUUM CHECK VALVE
DESCRIPTION...........................28
OPERATION.............................28
REMOVAL..............................29
INSTALLATION...........................29
VACUUM RESERVOIR
DESCRIPTION...........................29
OPERATION.............................29
REMOVAL..............................30
INSTALLATION...........................30
BR/BECONTROLS 24 - 9

CONTROLS
DIAGNOSIS AND TESTING - VACUUM SYSTEM
Vacuum control is used to operate the mode doors
in the heater-only and HVAC housings. Testing of the
heater-only and a/c heater mode control switch oper-
ation will determine if the vacuum, electrical, and
mechanical controls are functioning. However, it is
possible that a vacuum control system that operates
perfectly at engine idle (high engine vacuum) may
not function properly at high engine speeds or loads
(low engine vacuum). This can be caused by leaks in
the vacuum system, or by a faulty or improperly
installed vacuum check valve.
A vacuum system test will help to identify the
source of poor vacuum system performance or vac-
uum system leaks. Before starting this test, stop the
engine and make certain that the problem is not a
disconnected vacuum supply tube at the engine vac-
uum source or the vacuum reservoir.
Use an adjustable vacuum test set (Special Tool
C-3707) and a suitable vacuum pump to test the
HVAC vacuum control system. With a finger placed
over the end of the vacuum test hose probe (Fig. 1),
adjust the bleed valve on the test set gauge to obtain
a vacuum of exactly 27 kPa (8 in. Hg.). Release and
block the end of the probe several times to verify that
the vacuum reading returns to the exact 27 kPa (8
in. Hg.) setting. Otherwise, a false reading will be
obtained during testing.
VACUUM CHECK VALVE
(1) Remove the vacuum check valve. On gasoline
engines, one valve is located in the vacuum supply
tube (black) at the intake manifold tap on the right
side of the engine. A second check valve is located
next to the tee fitting in the vacuum supply tube
(black) near the dash panel in the engine compart-
ment. On diesel engines, the vacuum check valve is
integral to the engine vacuum pump nipple and is
threaded into the vacuum pump. The vacuum check
valve must be removed in order to perform the fol-
lowing tests. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS/VACUUM CHECK VALVE -
REMOVAL)
(2) Connect the test set vacuum supply hose to the
a/c heater control side of the valve. When connected
to this side of the check valve, no vacuum should
pass and the test set gauge should return to the 27kPa (8 in. Hg.) setting. If OK, go to step Step 3. If
not OK, replace the faulty valve.
(3) Connect the test set vacuum supply hose to the
engine vacuum side of the valve. When connected to
this side of the check valve, vacuum should flow
through the valve without restriction. If not OK,
replace the faulty valve.
A/C HEATER CONTROLS
(1) Connect the test set vacuum probe to the
HVAC vacuum supply (black) tube in the engine com-
partment. Position the test set gauge so that it can
be viewed from the passenger compartment.
(2) Place the a/c heater mode control switch knob
to each mode position, one position at a time, and
pause after each selection. The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after
each selection is made. If not OK, a component or
vacuum line in the vacuum circuit of the selected
mode has a leak. See Locating Vacuum Leaks below.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
Fig. 1 ADJUST VACUUM TEST BLEED VALVE
1 - VACUUM PUMP TOOL C-4289
2 - VACUUM TEST SET C-3707
3 - BLEED VALVE
4 - PROBE
24 - 10 CONTROLSBR/BE