ABS DODGE RAM 2002 Service Repair Manual

(5) Install rear planetary gear in rear annulus
gear (Fig. 205). Be sure planetary carrier is seated
against annulus gear.
(6) Install tabbed thrust washer on front face of
rear planetary gear (Fig. 206). Seat washer tabs in
matching slots in face of gear carrier. Use extra
petroleum jelly to hold washer in place if desired.
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.(8) Install sun gear and driving shell on interme-
diate shaft (Fig. 207). Seat shell against rear plane-
tary gear. Verify that thrust washer on planetary
gear was not displaced during installation.
(9) Install tabbed thrust washer in driving shell
(Fig. 208), be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
washer in place if desired.
(10) Install tabbed thrust washer on front plane-
tary gear (Fig. 209). Seat washer tabs in matching
slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
Fig. 202 Sun Gear Installation
1 - DRIVING SHELL
2 - SUN GEAR
3 - THRUST PLATE
4 - SUN GEAR REAR RETAINING RING
Fig. 203 Installing Rear Annulus Gear On
Intermediate Shaft
1 - REAR ANNULUS GEAR
2 - OUTPUT SHAFT
Fig. 204 Installing Rear Annulus Thrust Plate
1 - REAR ANNULUS GEAR
2 - THRUST PLATE
Fig. 205 Installing Rear Planetary Gear
1 - REAR ANNULUS GEAR
2 - REAR PLANETARY GEAR
21 - 372 AUTOMATIC TRANSMISSION - 47REBR/BE
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(22) Carefully rotate 3-4 accumulator housing
upward and remove 3-4 shift valve spring and con-
verter clutch valve plug and spring (Fig. 280).
(23) Remove left-side screw and remove 3-4 accu-
mulator housing from valve body (Fig. 281).
(24) Bend back tabs on boost valve tube brace (Fig.
282).
(25) Remove boost valve connecting tube (Fig.
283). Disengage tube from upper housing port first.
Then rock opposite end of tube back and forth to
work it out of lower housing.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(26) Turn valve body over so lower housing is fac-
ing upward (Fig. 284). In this position, the two check
balls in upper housing will remain in place and not
fall out when lower housing and separator plate are
removed.
(27) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
284). Note position of boost valve tube brace for
assembly reference.
(28) Remove lower housing and overdrive separa-
tor plate from transfer plate (Fig. 284).
Fig. 280 3-4 Shift And Converter Clutch Valve
Springs and Plug
1 - ACCUMULATOR HOUSING
2 - CONVERTER CLUTCH VALVE SPRING
3 - CLUTCH VALVE PLUG
4 - 3-4 SHIFT VALVE SPRING
Fig. 281 Accumulator Housing, Valve Springs, and
Plug
1 - 3-4 SHIFT VALVE SPRING
2 - CONVERTER CLUTCH VALVE SPRING AND PLUG
3 - 3-4 ACCUMULATOR HOUSING
Fig. 282 Boost Valve Tube Brace
1 - BOOST VALVE TUBE
2 - TUBE BRACE (DOUBLE TAB)
Fig. 283 Boost Valve Tube
1 - BOOST VALVE TUBE
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
21 - 414 AUTOMATIC TRANSMISSION - 47REBR/BE
VALVE BODY (Continued)

(c) Hold shuttle valve in place.
(d) Compress secondary spring and install E-clip
in groove at end of shuttle valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(8) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N´m (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 valve governor plugs in
valve body.
(10) Install shuttle valve primary spring and
throttle plug.
(11) Align and install governor plug cover. Tighten
cover screws to 4 N´m (35 in. lbs.) torque.
BOOST VALVE TUBE AND BRACE
(1) Position valve body assembly so lower housing
is facing upward (Fig. 306).(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. 306).
(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. 307).
(6) Install and finger tighten three screws that
secure tube brace to valve body housings (Fig. 307).
(7) Bend tube brace tabs up and against tube to
hold it in position (Fig. 308).
(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.
Fig. 304 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 - 424 AUTOMATIC TRANSMISSION - 47REBR/BE
VALVE BODY (Continued)

3-4 ACCUMULATOR
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 309).
(2) Loosely attach accumulator housing with right-
side screw (Fig. 309). 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. 310). Tighten screws to 4 N´m (35 in. lbs.).
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. 311).
(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. 312).
(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.
Fig. 308 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWNFig. 309 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. 310 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
21 - 426 AUTOMATIC TRANSMISSION - 47REBR/BE
VALVE BODY (Continued)

(13) Remove input gear pilot bearing by inserting
a suitably sized drift into the splined end of the input
gear and driving the bearing out with the drift and a
hammer (Fig. 53).
(14) Install new pilot bearing with Plug C-293-3.
(15) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 54).
(16) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 55). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 56).
INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 57)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 57). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
Fig. 53 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 54 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 55 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
BR/BETRANSFER CASE - NV241LD 21 - 447
TRANSFER CASE - NV241LD (Continued)

INPUT AND PLANETARY GEAR
(1) Lubricate planetary components with transmis-
sion fluid.
(2) Install first thrust washer in carrier (Fig. 55).
Lube washer with petroleum jelly before installation.
(3) Support carrier with wood blocks under PTO
gear (Fig. 56).
(4) Install support sleeve in planetary carrier. Be
sure sleeve is seated.
Fig. 53 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 54 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 55 Thrust Washer Installation
1 - THRUST WASHER
2 - TABS IN SLOTS
Fig. 56 Support Sleeve Installation
1 - PLANETARY
2 - SUPPORT SLEEVE
3 - WOOD BLOCKS
BR/BETRANSFER CASE - NV241HD 21 - 483
TRANSFER CASE - NV241HD (Continued)

(5) Install input gear in planetary carrier (Fig. 57).
(6) Install second thrust washer in planetary car-
rier. Be sure washer tabs are seated in carrier slots.
(7) Install lock ring (Fig. 58).(8) Install retaining ring (Fig. 59).
INPUT AND PLANETARY GEAR
(1) Lubricate planetary pinions and annulus gear
with transmission fluid.
(2) Install planetary/input gear assembly in case
(Fig. 60).
(3) Start planetary pinions in low range annulus
gear. Then tap PTO gear, with hammer handle to
seat planetary pinions in annulus gear.
Fig. 57 Input Gear And Thrust Washer Installation
1 - INPUT GEAR
2 - THRUST WASHER
3 - TABS IN SLOTS
Fig. 58 Lock Ring Installation
1 - LOCK RING (BE SURE TABS ARE SEATED IN SLOTS)
Fig. 59 Retaining Ring Installation
1 - RETAINING RING
Fig. 60 Planetary/Input Gear Assembly Installation
1 - WOOD/RUBBER HAMMER HANDLE
2 - PLANETARY ASSEMBLY
21 - 484 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

DOOR - CARGO
TABLE OF CONTENTS
page page
AIR EXHAUSTER
REMOVAL.............................77
INSTALLATION.........................77
CHECK
REMOVAL.............................78
INSTALLATION.........................78
DOOR
REMOVAL.............................78
INSTALLATION.........................78
ADJUSTMENTS
ADJUSTMENT - CARGO DOOR..........78
EXHAUST VENT
REMOVAL.............................79
INSTALLATION.........................79
HINGE
REMOVAL.............................79
INSTALLATION.........................80
INSIDE HANDLE ACTUATOR
REMOVAL.............................80
INSTALLATION.........................80
LATCH - LOWER
REMOVAL.............................80
INSTALLATION.........................80
LATCH - UPPER
REMOVAL.............................81INSTALLATION.........................81
LATCH STRIKER - LOWER
REMOVAL.............................82
INSTALLATION.........................82
LATCH STRIKER - UPPER
REMOVAL.............................82
INSTALLATION.........................82
RELEASE CABLE
REMOVAL.............................82
INSTALLATION.........................82
SHUTFACE HANDLE
REMOVAL.............................83
INSTALLATION.........................83
TRIM PANEL
REMOVAL.............................83
INSTALLATION.........................84
VENT WINDOW
REMOVAL.............................85
INSTALLATION.........................85
WATERDAM
REMOVAL.............................85
INSTALLATION.........................85
AIR EXHAUSTER
REMOVAL
(1) Remove cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - REMOVAL).
(2) Peel back waterdam.
(3) Remove push-in fastener attaching air
exhauster to cargo door inner panel (Fig. 1).
(4) Separate air exhauster from cargo door.
INSTALLATION
(1) Position air exhauster in cargo door.
(2) Engage air exhauster upper tabs with cargo
door inner panel.
(3) Install push-in fastener attaching air exhauster
to cargo door inner panel (Fig. 1).
(4) Reposition waterdam.
(5) Install cargo door trim panel (Refer to 23 -
BODY/DOOR - CARGO/TRIM PANEL - INSTALLA-
TION).
Fig. 1 Cargo Door Air Exhauster
1 - CARGO DOOR
2 - PUSHÐIN FASTENER
3 - DOOR EXHAUSTER
4-TAB
BR/BEDOOR - CARGO 23 - 77

sary, loosen the other C-pillar to hinge bolts and
move the door to the correct position.
(4) Tighten the bolts to 28 N´m (21 ft. lbs.) torque.
(5) If necessary, loosen the bolts attaching the
lower striker and move striker to the correct position.
(6)
If necessary, loosen the bolts attaching the upper
latch to the cargo door and move to the correct posi-
tion. (Fig. 4)
CARGO DOOR IN/OUT
(1) Loosen the applicable hinge to door fasteners
and move the door to the correct position.
(2) Tighten the bolts to 28 N´m (21 ft. lbs.) torque.
EXHAUST VENT
REMOVAL
(1) Using a trim stick, carefully pry bottom of vent
to disengage from door (Fig. 5).
(2) Separate vent from door.
INSTALLATION
(1) Position upper side of vent in door opening.
(2) Slide upward until tabs on top edge are in
place.
(3) Push the lower side of the vent towards the
door until the tabs snap into place.
(4) Ensure vent is fully seated.
HINGE
REMOVAL
(1) Remove cargo door (Refer to 23 - BODY/DOOR
- CARGO/DOOR - REMOVAL).
(2) Remove quarter trim panel (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL).
(3) Remove bolts attaching hinge to C-pillar (Fig.
6).
(4) Separate hinge from vehicle.
Fig. 4 CARGO DOOR UPPER LATCH
1 - UPPER LATCH
2 - ADJUSTMENT SLOTS
3 - CARGO DOOR
Fig. 5 Cargo Door Exhaust Vent
1 - CARGO DOOR
2 - EXHAUST VENT
Fig. 6 Cargo Door Hinge
1 - CARGO DOOR
2 - CAB
3 - UPPER HINGE
4 - LOWER HINGE
5 - DOOR CHECK
BR/BEDOOR - CARGO 23 - 79
DOOR (Continued)

EXTERIOR
TABLE OF CONTENTS
page page
EXTERIOR
DESCRIPTION.........................86
OPERATION...........................86
BODY SIDE MOLDINGS
REMOVAL.............................86
INSTALLATION.........................87
BODY STRIPES AND DECALS
REMOVAL.............................87
INSTALLATION.........................87
TAPE STRIPE
REMOVAL.............................88
INSTALLATION.........................89
EXTERIOR NAME PLATES
REMOVAL.............................89
INSTALLATION.........................89
COWL GRILLE
REMOVAL.............................90
INSTALLATION.........................90
ROOF JOINT MOLDING
REMOVAL.............................91
INSTALLATION.........................91
GRILLE
REMOVAL.............................91
INSTALLATION.........................91
GRILLE FRAME
REMOVAL.............................91
INSTALLATION.........................92
FRONT END SPLASH SHIELDS
REMOVAL.............................92
INSTALLATION.........................92LEFT FRONT FENDER
REMOVAL.............................93
INSTALLATION.........................93
RIGHT FRONT FENDER
REMOVAL.............................94
INSTALLATION.........................94
FUEL FILL DOOR
REMOVAL.............................95
INSTALLATION.........................95
REAR FENDER
REMOVAL.............................95
INSTALLATION.........................95
REAR SPLASH SHIELD
REMOVAL.............................96
INSTALLATION.........................96
REAR WHEELHOUSE LINER
REMOVAL.............................96
INSTALLATION.........................96
CARGO BOX
REMOVAL.............................97
INSTALLATION.........................97
SIDE VIEW MIRROR
REMOVAL.............................97
INSTALLATION.........................98
SIDE VIEW MIRROR - LOW MOUNTED
REMOVAL.............................98
INSTALLATION.........................98
SIDE VIEW MIRROR GLASS
REMOVAL.............................98
INSTALLATION.........................98
EXTERIOR
DESCRIPTION
Exterior sheet metal components make up the
exterior of the vehicle. Some exterior metal systems
are welded assemblies, such as doors and hoods.
Some exterior trim items are made of composite.
OPERATION
The exterior is finished in various metal stampings
and composite moldings. These assemblies give the
vehicle a finished appearance and protect the occu-
pants from the elements. Some components are part
of the energy absorbing system used to protect the
occupants in collisions. The exterior sheet metal is
repairable and adjustable for fit and finish. Welded
and bonded component systems are adjustable as asystem. Trim components made of composite are
stamped with the type of material used.
DaimlerChrysler uses various fasteners to retain
trim items. At times, it is not possible to remove trim
items without damaging the fastener. If it is not pos-
sible to remove an item without damaging a compo-
nent, cut or break the fasteners and use new ones
when installing the component.BODY SIDE MOLDINGS
REMOVAL
(1) Warm the effected stick-on molding and body
metal to approximately 38ÉC (100ÉF) using a suitable
heat lamp or heat gun.
(2) Pull stick-on molding from painted surface
(Fig. 1) and (Fig. 2).
23 - 86 EXTERIORBR/BE