lock DODGE RAM 2001 Service Repair Manual

(7) Install thrust bearing in overdrive unit sliding
hub. Use petroleum jelly to hold bearing in position.
CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Align-
ment Tool 6227-2. Overdrive unit cannot be installed
if splines are not aligned. If splines have rotated out
of alignment, unit will have to be disassembled to
realign splines.
(9) Carefully slide Alignment Tool 6227-2 out of
overdrive planetary gear and overrunning clutch
splines.
(10) Raise overdrive unit and carefully slide it
straight onto intermediate shaft. Insert park rod into
park lock reaction plug at same time. Avoid tilting
overdrive during installation as this could cause
planetary gear and overrunning clutch splines to
rotate out of alignment. If this occurs, it will be nec-
essary to remove and disassemble overdrive unit to
realign splines.
(11) Work overdrive unit forward on intermediate
shaft until seated against transmission case.
(12) Install bolts attaching overdrive unit to trans-
mission unit. Tighten bolts in diagonal pattern to 34
N´m (25 ft-lbs).
(13) Connect the transmission speed sensor and
overdrive wiring connectors.
(14) Install the transfer case, if equipped.
(15) Align and install rear propeller shaft, if nec-
essary. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION)
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunning clutch (Fig. 179) consists of an
inner race, an outer race (or cam), rollers and
springs, and the spring retainer. The number of roll-
ers and springs depends on what transmission and
which overrunning clutch is being dealt with.
OPERATION
As the inner race is rotated in a clockwise direction
(as viewed from the front of the transmission), the
race causes the rollers to roll toward the springs,
causing them to compress against their retainer. The
compression of the springs increases the clearance
between the rollers and cam. This increased clear-
ance between the rollers and cam results in a free-
wheeling condition. When the inner race attempts to
rotate counterclockwise, the action causes the rollers
to roll in the same direction as the race, aided by the
pushing of the springs. As the rollers try to move in
the same direction as the inner race, they are
wedged between the inner and outer races due to the
design of the cam. In this condition, the clutch is
locked and acts as one unit.
DISASSEMBLY
NOTE: To service the overrunning clutch cam and
the overdrive piston retainer, the transmission
geartrain and the overdrive unit must be removed
from the transmission.
Fig. 179 Overrunning Clutch
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 405
OVERDRIVE UNIT (Continued)

OPERATION
The principal which makes this operation possible
is known as Pascal's Law. Pascal's Law can be stated
as: ªPressure on a confined fluid is transmitted
equally in all directions and acts with equal force on
equal areas.º
PRESSURE
Pressure (Fig. 188) is nothing more than force
(lbs.) divided by area (in or ft.), or force per unit
area. Given a 100 lb. block and an area of 100 sq. in.
on the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.
PRESSURE ON A CONFINED FLUID
Pressure is exerted on a confined fluid (Fig. 189)
by applying a force to some given area in contact
with the fluid. A good example of this is a cylinder
filled with fluid and equipped with a piston that is
closely fitted to the cylinder wall. If a force is applied
to the piston, pressure will be developed in the fluid.
Of course, no pressure will be created if the fluid is
not confined. It will simply ªleakº past the piston.
There must be a resistance to flow in order to create
pressure. Piston sealing is extremely important in
hydraulic operation. Several kinds of seals are used
to accomplish this within a transmission. These
include but are not limited to O-rings, D-rings, lip
seals, sealing rings, or extremely close tolerances
between the piston and the cylinder wall. The force
exerted is downward (gravity), however, the principle
remains the same no matter which direction is taken.The pressure created in the fluid is equal to the force
applied, divided by the piston area. If the force is 100
lbs., and the piston area is 10 sq. in., then the pres-
sure created equals 10 PSI. Another interpretation of
Pascal's Law is that regardless of container shape or
size, the pressure will be maintained throughout, as
long as the fluid is confined. In other words, the
pressure in the fluid is the same everywhere within
the container.
FORCE MULTIPLICATION
Using the 10 PSI example used in the illustration
(Fig. 190), a force of 1000 lbs. can be moved with a
force of only 100 lbs. The secret of force multiplica-
tion in hydraulic systems is the total fluid contact
area employed. The illustration, (Fig. 190), shows an
area that is ten times larger than the original area.
The pressure created with the smaller 100 lb. input
is 10 PSI. The concept ªpressure is the same every-
whereº means that the pressure underneath the
larger piston is also 10 PSI. Pressure is equal to the
force applied divided by the contact area. Therefore,
by means of simple algebra, the output force may be
found. This concept is extremely important, as it is
also used in the design and operation of all shift
valves and limiting valves in the valve body, as well
as the pistons, of the transmission, which activate
the clutches and bands. It is nothing more than
using a difference of area to create a difference in
pressure to move an object.
Fig. 188 Force and Pressure Relationship
Fig. 189 Pressure on a Confined Fluid
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 409
PISTONS (Continued)

DISASSEMBLY
(1) Remove planetary snap-ring (Fig. 193).
(2) Remove front annulus and planetary assembly
from driving shell (Fig. 193).
(3) Remove snap-ring that retains front planetary
gear in annulus gear (Fig. 194).
(4) Remove tabbed thrust washer and tabbed
thrust plate from hub of front annulus (Fig. 195).
(5) Separate front annulus and planetary gears
(Fig. 195).
(6) Remove front planetary gear front thrust
washer from annulus gear hub.
(7) Separate and remove driving shell, rear plane-
tary and rear annulus from output shaft (Fig. 196).
(8) Remove front planetary rear thrust washer
from driving shell.
(9) Remove tabbed thrust washers from rear plan-
etary gear.
(10) Remove lock ring that retains sun gear in
driving shell. Then remove sun gear, spacer and
thrust plates.
INSPECTION
Check sun gear and driving shell condition.
Replace the gear if damaged or if the bushings are
scored or worn. The bushings are not serviceable.
Replace the driving shell if worn, cracked or dam-
aged.
Replace planetary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace the annulus
gears and supports if either component is worn or
damaged.
Fig. 193 Front Annulus And Planetary Assembly
Removal
1 - DRIVING SHELL
2 - FRONT ANNULUS AND PLANETARY ASSEMBLY
3 - PLANETARY SNAP-RING
Fig. 194 Front Planetary Snap-Ring Removal
1 - FRONT ANNULUS GEAR
2 - PLANETARY SNAP-RING
Fig. 195 Front Planetary And Annulus Gear
Disassembly
1 - FRONT ANNULUS
2 - THRUST WASHER
3 - THRUST PLATE
4 - FRONT THRUST WASHER
5 - FRONT PLANETARY
Fig. 196 Removing Driving Shell, Rear Planetary
And Rear Annulus
1 - REAR ANNULUS
2 - REAR PLANETARY
3 - DRIVING SHELL
4 - OUTPUT SHAFT
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 411
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(9) Hold sun gear in place and install thrust plate
over sun gear at rear of driving shell (Fig. 202).
(10) Position wood block on bench and support sun
gear on block (Fig. 203). This makes it easier to align
and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play
check.
(11) Align rear thrust plate on driving shell and
install sun gear lock ring. Be sure ring is fully seated
in sun gear ring groove (Fig. 204).
(12) Install assembled driving shell and sun gear
on output shaft (Fig. 205).
(13) Install rear thrust washer on front planetary
gear (Fig. 206). Use enough petroleum jelly to hold
washer in place and be sure all four washer tabs are
seated.
Fig. 199 Installing Rear Planetary Front Thrust
Washer
1 - FRONT TABBED THRUST WASHER
2 - REAR PLANETARY GEAR
Fig. 200 Installing Spacer On Sun Gear
1 - SUN GEAR
2 - SUN GEAR SPACER
Fig. 201 Installing Driving Shell Front Thrust Plate
On Sun Gear
1 - SPACER
2 - SUN GEAR
3 - THRUST PLATE
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 413
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

Fig. 202 Installing Driving Shell Rear Thrust Plate
1 - DRIVING SHELL
2 - SUN GEAR
3 - REAR THRUST PLATE
Fig. 203 Supporting Sun Gear On Wood Block
1 - SUN GEAR
2 - DRIVING SHELL
3 - WOOD BLOCK
Fig. 204 Installing Sun Gear Lock Ring
1 - LOCK RING GROOVE
2 - SUN GEAR LOCK RING
3 - DRIVING SHELL
4 - REAR THRUST PLATE
Fig. 205 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
1 - SUN GEAR/DRIVING SHELL ASSEMBLY
2 - OUTPUT SHAFT
21 - 414 AUTOMATIC TRANSMISSION - 44REBR/BE
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(14) Install front planetary gear on output shaft
and in driving shell (Fig. 207).
(15) Install front thrust washer on front planetary
gear. Use enough petroleum jelly to hold washer in
place and be sure all four washer tabs are seated.
(16) Assemble front annulus gear and support, if
necessary. Be sure support snap-ring is seated.
(17) Install front annulus on front planetary (Fig.
207).
(18) Position thrust plate on front annulus gear
support (Fig. 208). Note that plate has two tabs on it.
These tabs fit in notches of annulus hub.
(19) Install thrust washer in front annulus (Fig.
209). Align flat on washer with flat on planetary hub.
Also be sure washer tab is facing up.
(20) Install front annulus snap-ring (Fig. 210). Use
snap-ring pliers to avoid distorting ring during
installation. Also be sure ring is fully seated.
(21) Install planetary selective snap-ring with
snap-ring pliers (Fig. 211). Be sure ring is fully
seated.(22) Turn planetary geartrain assembly over so
driving shell is facing workbench. Then support
geartrain on wood block positioned under forward
end of output shaft. This allows geartrain compo-
nents to move forward for accurate end play check.
(23) Check planetary geartrain end play with
feeler gauge (Fig. 212). Gauge goes between shoulder
on output shaft and end of rear annulus support.
(24) Geartrain end play should be 0.12 to 1.22 mm
(0.005 to 0.048 in.). If end play is incorrect, snap-ring
(or thrust washers) may have to be replaced. Snap-
rings are available in three different thicknesses for
adjustment purposes.
Fig. 206 Installing Rear Thrust Washer On Front
Planetary Gear
1 - FRONT PLANETARY GEAR
2 - REAR TABBED THRUST WASHER
Fig. 207 Installing Front Planetary And Annulus
Gears
1 - FRONT PLANETARY GEAR
2 - FRONT THRUST WASHER
3 - FRONT ANNULUS GEAR
Fig. 208 Positioning Thrust Plate On Front Annulus
Support
1 - FRONT ANNULUS
2 - THRUST PLATE
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 415
PLANETARY GEARTRAIN/OUTPUT SHAFT (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)

ADJUSTMENT
Check linkage adjustment by starting engine in
PARK and NEUTRAL. Adjustment is acceptable if
the engine starts in only these two positions. Adjust-
ment is incorrect if the engine starts in one position
but not both positions
If the engine starts in any other position, or if the
engine will not start in any position, the park/neutral
switch is probably faulty.
LINKAGE ADJUSTMENT
Check condition of the shift linkage (Fig. 225). Do
not attempt adjustment if any component is loose,
worn, or bent. Replace any suspect components.
Replace the grommet securing the shift rod or
torque rod in place if either rod was removed from
the grommet. Remove the old grommet as necessary
and use suitable pliers to install the new grommet.
(1) Shift transmission into PARK.
(2) Raise and support vehicle.
(3) Loosen lock bolt in front shift rod adjusting
swivel (Fig. 225).
(4) Ensure that the shift rod slides freely in the
swivel. Lube rod and swivel as necessary.
(5) Move transmission shift lever fully rearward to
the Park detent.
(6) Center adjusting swivel on shift rod.
(7) Tighten swivel lock bolt to 10 N´m (90 in. lbs.).
(8) Lower vehicle and verify proper adjustment.
SOLENOID
DESCRIPTION
The typical electrical solenoid used in automotive
applications is a linear actuator. It is a device that
produces motion in a straight line. This straight line
motion can be either forward or backward in direc-
tion, and short or long distance.
A solenoid is an electromechanical device that uses
a magnetic force to perform work. It consists of a coil
of wire, wrapped around a magnetic core made from
steel or iron, and a spring loaded, movable plunger,
which performs the work, or straight line motion.
The solenoids used in transmission applications
are attached to valves which can be classified asnor-
mally openornormally closed. Thenormally
opensolenoid valve is defined as a valve which
allows hydraulic flow when no current or voltage is
applied to the solenoid. Thenormally closedsole-
noid valve is defined as a valve which does not allow
hydraulic flow when no current or voltage is applied
to the solenoid. These valves perform hydraulic con-
trol functions for the transmission and must there-
fore be durable and tolerant of dirt particles. For
these reasons, the valves have hardened steel pop-pets and ball valves. The solenoids operate the valves
directly, which means that the solenoids must have
very high outputs to close the valves against the siz-
able flow areas and line pressures found in current
transmissions. Fast response time is also necessary
to ensure accurate control of the transmission.
The strength of the magnetic field is the primary
force that determines the speed of operation in a par-
ticular solenoid design. A stronger magnetic field will
cause the plunger to move at a greater speed than a
weaker one. There are basically two ways to increase
the force of the magnetic field:
²Increase the amount of current applied to the
coil or
²Increase the number of turns of wire in the coil.
The most common practice is to increase the num-
ber of turns by using thin wire that can completely
fill the available space within the solenoid housing.
The strength of the spring and the length of the
plunger also contribute to the response speed possi-
ble by a particular solenoid design.
A solenoid can also be described by the method by
which it is controlled. Some of the possibilities
include variable force, pulse-width modulated, con-
stant ON, or duty cycle. The variable force and pulse-
width modulated versions utilize similar methods to
control the current flow through the solenoid to posi-
tion the solenoid plunger at a desired position some-
Fig. 225 Linkage Adjustment Components
1 - FRONT SHIFT ROD
2 - TORQUE SHAFT ASSEMBLY
3 - TORQUE SHAFT ARM
4 - ADJUSTING SWIVEL
5 - LOCK BOLT
BR/BEAUTOMATIC TRANSMISSION - 44RE 21 - 423
SHIFT MECHANISM (Continued)

where between full ON and full OFF. The constant
ON and duty cycled versions control the voltage
across the solenoid to allow either full flow or no flow
through the solenoid's valve.
OPERATION
When an electrical current is applied to the sole-
noid coil, a magnetic field is created which produces
an attraction to the plunger, causing the plunger to
move and work against the spring pressure and the
load applied by the fluid the valve is controlling. The
plunger is normally directly attached to the valve
which it is to operate. When the current is removed
from the coil, the attraction is removed and the
plunger will return to its original position due to
spring pressure.
The plunger is made of a conductive material and
accomplishes this movement by providing a path for
the magnetic field to flow. By keeping the air gap
between the plunger and the coil to the minimum
necessary to allow free movement of the plunger, the
magnetic field is maximized.
SPEED SENSOR
DESCRIPTION
The speed sensor (Fig. 226) is located in the over-
drive gear case. The sensor is positioned over the
park gear and monitors transmission output shaft
rotating speed.
OPERATION
Speed sensor signals are triggered by the park
gear lugs as they rotate past the sensor pickup face.
Input signals from the sensor are sent to the trans-
mission control module for processing. Signals from
this sensor are shared with the powertrain control
module.
THROTTLE VALVE CABLE
DESCRIPTION
Transmission throttle valve cable (Fig. 227) adjust-
ment is extremely important to proper operation.
This adjustment positions the throttle valve, which
controls shift speed, quality, and part-throttle down-
shift sensitivity.
If cable setting is too loose, early shifts and slip-
page between shifts may occur. If the setting is too
tight, shifts may be delayed and part throttle down-
shifts may be very sensitive.
The transmission throttle valve is operated by a
cam on the throttle lever. The throttle lever is oper-
ated by an adjustable cable (Fig. 228). The cable is
attached to an arm mounted on the throttle lever
shaft. A retaining clip at the engine-end of the cable
is removed to provide for cable adjustment. The
retaining clip is then installed back onto the throttle
valve cable to lock in the adjustment.
Fig. 226 Transmission Output Speed Sensor
1 - TRANSMISSION OUTPUT SHAFT SPEED SENSOR
2 - SEAL
Fig. 227 Throttle Valve Cable Attachment - At
Engine
1 - THROTTLE VALVE CABLE
2 - CABLE BRACKET
3 - THROTTLE BODY LEVER
4 - ACCELERATOR CABLE
5 - SPEED CONTROL CABLE
21 - 424 AUTOMATIC TRANSMISSION - 44REBR/BE
SOLENOID (Continued)