DODGE RAM 2002 Service Repair Manual

DISASSEMBLY
(1) Remove planetary snap-ring from intermediate
shaft (Fig. 202). Discard snap-ring as it is not reus-
able.
(2) Remove front planetary gear and front annulus
gear as assembly (Fig. 203).
(3) Remove front planetary gear and thrust
washer from front annulus gear (Fig. 204). Note
thrust washer position for assembly reference.
(4) Remove tabbed thrust washer from driving
shell (Fig. 205). Note washer position for assembly
reference.
(5) Remove sun gear and driving shell as assembly
(Fig. 206).
(6) Remove tabbed thrust washer from rear plane-
tary gear (Fig. 207). Note washer position on gear for
assembly reference.
(7) Remove rear planetary gear and rear annulus
gear from intermediate shaft (Fig. 208).
(8) Remove thrust plate from rear annulus gear
(Fig. 209).
Fig. 202 Removing Planetary Snap-Ring
1 - PLANETARY SNAP-RING
Fig. 203 Removing Front Planetary And Annulus
Gears
1 - DRIVING SHELL
2 - FRONT ANNULUS GEAR
3 - FRONT PLANETARY GEAR
Fig. 204 Disassembling Front Planetary And
Annulus Gears
1 - FRONT PLANETARY GEAR
2 - TABBED THRUST WASHER
3 - FRONT ANNULUS GEAR
Fig. 205 Driving Shell Thrust Washer Removal
1 - DRIVING SHELL
2 - TABBED THRUST WASHER
3 - SUN GEAR
21 - 198 AUTOMATIC TRANSMISSION - 46REBR/BE
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

INSPECTION
Inspect the planetary gear sets and annulus gears.
The planetary pinions, shafts, washers, and retaining
pins are serviceable. However, if a pinion carrier is
damaged, the entire planetary gear set must be
replaced as an assembly.
Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash-
ers if cracked, scored or worn.
Inspect the machined surfaces of the intermediate
shaft. Be sure the oil passages are open and clear.
Replace the shaft if scored, pitted, or damaged.
Inspect the sun gear and driving shell. If either
component is worn or damaged, remove the sun gear
rear retaining ring and separate the sun gear andthrust plate from the driving shell. Then replace the
necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as
an assembly if the bushings are scored or worn. The
sun gear bushings are not serviceable. Replace the
thrust plate if worn, or severely scored. Replace the
driving shell if distorted, cracked, or damaged in any
way.
Replace all snap-rings during geartrain assembly.
Reusing snap-rings is not recommended.
ASSEMBLY
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly to lubricate intermediate shaft bushing surfaces,
thrust washers and thrust plates and to hold these
parts in place during assembly.
Fig. 206 Sun Gear And Driving Shell Removal
1 - INTERMEDIATE SHAFT
2 - DRIVING SHELL
3 - SUN GEAR
Fig. 207 Rear Planetary Thrust Washer Removal
1 - SUN GEAR
2 - REAR PLANETARY THRUST WASHER
3 - DRIVING SHELL
Fig. 208 Rear Planetary And Annulus Gear Removal
1 - INTERMEDIATE SHAFT
2 - REAR ANNULUS GEAR
3 - REAR PLANETARY GEAR
Fig. 209 Rear Annulus Thrust Plate Removal
1 - REAR ANNULUS GEAR
2 - THRUST PLATE
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 199
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(2) Install front snap-ring on sun gear and install
gear in driving shell. Then install thrust plate over
sun gear and against rear side of driving shell (Fig.
210). Install rear snap-ring to secure sun gear and
thrust plate in driving shell.
(3) Install rear annulus gear on intermediate shaft
(Fig. 211).
(4)
Install thrust plate in annulus gear (Fig. 212). Be
sure plate is seated on shaft splines and against gear.
(5) Install rear planetary gear in rear annulus
gear (Fig. 213). Be sure planetary carrier is seated
against annulus gear.
(6) Install tabbed thrust washer on front face of
rear planetary gear (Fig. 214). 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. 215). 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. 216), be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
washer in place if desired.
Fig. 210 Sun Gear Installation
1 - DRIVING SHELL
2 - SUN GEAR
3 - THRUST PLATE
4 - SUN GEAR REAR RETAINING RING
Fig. 211 Installing Rear Annulus Gear On
Intermediate Shaft
1 - REAR ANNULUS GEAR
2 - OUTPUT SHAFT
Fig. 212 Installing Rear Annulus Thrust Plate
1 - REAR ANNULUS GEAR
2 - THRUST PLATE
21 - 200 AUTOMATIC TRANSMISSION - 46REBR/BE
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(10) Install tabbed thrust washer on front plane-
tary gear (Fig. 217). Seat washer tabs in matching
slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
Fig. 213 Installing Rear Planetary Gear
1 - REAR ANNULUS GEAR
2 - REAR PLANETARY GEAR
Fig. 214 Installing Rear Planetary Thrust Washer
1 - REAR PLANETARY GEAR
2 - TABBED THRUST WASHER
Fig. 215 Installing Sun Gear And Driving Shell
1 - OUTPUT SHAFT
2 - DRIVING SHELL
3 - REAR PLANETARY GEAR
4 - OUTPUT SHAFT
5 - SUN GEAR
Fig. 216 Installing Driving Shell Thrust Washer
1 - TAB SLOTS (3)
2 - DRIVING SHELL
3 - TABBED THRUST WASHER
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 201
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(11) Install front annulus gear over and onto front
planetary gear (Fig. 218). Be sure gears are fully
meshed and seated.
(12) Install front planetary and annulus gear
assembly (Fig. 219). Hold gears together and slide
them onto shaft. Be sure planetary pinions are
seated on sun gear and that planetary carrier is
seated on intermediate shaft.
(13) Place geartrain in upright position. Rotate
gears to be sure all components are seated and prop-
erly assembled. Snap-ring groove at forward end of
intermediate shaft will be completely exposed when
components are assembled correctly.
(14) Install new planetary snap-ring in groove at
end of intermediate shaft (Fig. 220).
(15) Turn planetary geartrain over. Position wood
block under front end of intermediate shaft and sup-
port geartrain on shaft. Be sure all geartrain parts
have moved forward against planetary snap-ring.
This is important for accurate end play check.
(16) Check planetary geartrain end play with
feeler gauge (Fig. 221). Insert gauge between rear
annulus gear and shoulder on intermediate shaft as
shown. End play should be 0.15 to 1.22 mm (0.006 to
0.048 in.).
(17) If end play is incorrect, install thinner/thicker
planetary snap-ring as needed.
Fig. 217 Installing Thrust Washer On Front
Planetary Gear
1 - TABBED THRUST WASHER
2 - FRONT PLANETARY GEAR
Fig. 218 Assembling Front Planetary And Annulus
Gears
1 - FRONT ANNULUS GEAR
2 - FRONT PLANETARY GEAR
Fig. 219 Installing Front Planetary And Annulus
Gear Assembly
1 - DRIVING SHELL
2 - ASSEMBLED FRONT PLANETARY AND ANNULUS GEARS
21 - 202 AUTOMATIC TRANSMISSION - 46REBR/BE
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

REAR CLUTCH
DESCRIPTION
The rear clutch assembly (Fig. 222) is composed of
the rear clutch retainer, pressure plate, clutch plates,
driving discs, piston, Belleville spring, and snap-
rings. The Belleville spring acts as a lever to multi-
ply the force applied on to it by the apply piston. The
increased apply force on the rear clutch pack, in com-
parison to the front clutch pack, is needed to hold
against the greater torque load imposed onto the rear
pack. The rear clutch is directly behind the front
clutch and is considered a driving component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between
the clutch retainer and piston. The fluid pressure is
provided by the oil pump, transferred through the
control valves and passageways, and enters the
clutch through the hub of the reaction shaft support.
With pressure applied between the clutch retainer
and piston, the piston moves away from the clutch
retainer and compresses the clutch pack. This action
applies the clutch pack, allowing torque to flow
through the input shaft into the driving discs, and
into the clutch plates and pressure plate that are
lugged to the clutch retainer. The waved spring is
used to cushion the application of the clutch pack.
The snap-ring is selective and used to adjust clutch
pack clearance.
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.
Fig. 220 Installing Planetary Snap-Ring
1 - SNAP-RING PLIERS
2 - PLANETARY SNAP-RING
Fig. 221 Checking Planetary Geartrain End Play
1 - OUTPUT SHAFT
2 - REAR ANNULUS GEAR
3 - FEELER GAUGE
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 203
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

DISASSEMBLY
(1) Remove fiber thrust washer from forward side
of clutch retainer.
(2) Remove input shaft front and rear seal rings.
(3) Remove selective clutch pack snap-ring (Fig.
223).
(4) Remove the reaction plate, clutch discs, steel
plates, pressure plate, wave spring, spacer ring, and
piston spring (Fig. 223).
(5) Remove clutch piston with rotating motion.
(6) Remove and discard piston seals.
(7) Remove input shaft retaining ring. It may be
necessary to press the input shaft in slightly to
relieve tension on the retaining 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 shoptowels 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.
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.
Fig. 222 Rear Clutch Components
1 - REAR CLUTCH RETAINER 11 - REACTION PLATE
2 - TORLONŸ SEAL RINGS 12 - CLUTCH PLATES
3 - INPUT SHAFT 13 - WAVE SPRING
4 - PISTON RETAINER 14 - SPACER RING
5 - OUTPUT SHAFT THRUST WASHER 15 - PISTON
6 - INNER PISTON SEAL 16 - OUTER PISTON SEAL
7 - PISTON SPRING 17 - REAR SEAL RING
8 - PRESSURE PLATE 18 - FIBER THRUST WASHER
9 - CLUTCH DISCS 19 - RETAINING RING
10 - SNAP-RING (SELECTIVE)
21 - 204 AUTOMATIC TRANSMISSION - 46REBR/BE
REAR CLUTCH (Continued)

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.
(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 partially press
input shaft into retainer (Fig. 224). Use a suitably
sized press tool to support retainer as close to input
shaft as possible.
(4) Install input shaft retaining ring.
(5) Press the input shaft the remainder of the way
into the clutch retainer.
(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 quan-
tity 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.
Fig. 223 Rear Clutch Components
1 - REAR CLUTCH RETAINER 11 - REACTION PLATE
2 - TORLONŸ SEAL RINGS 12 - CLUTCH PLATES
3 - INPUT SHAFT 13 - WAVE SPRING
4 - PISTON RETAINER 14 - SPACER RING
5 - OUTPUT SHAFT THRUST WASHER 15 - PISTON
6 - INNER PISTON SEAL 16 - OUTER PISTON SEAL
7 - PISTON SPRING 17 - REAR SEAL RING
8 - PRESSURE PLATE 18 - FIBER THRUST WASHER
9 - CLUTCH DISCS 19 - RETAINING RING
10 - SNAP-RING (SELECTIVE)
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 205
REAR CLUTCH (Continued)

(9) Install piston spring in retainer and on top of
piston. Concave side of spring faces downward
(toward piston).
(10) Install the spacer ring and wave spring into
the retainer. Be sure spring is completely seated in
retainer groove.
(11) Install pressure plate (Fig. 223). Ridged side
of plate faces downward (toward piston) and flat side
toward clutch pack.
(12) Install first clutch disc in retainer on top of
pressure plate. Then install a clutch plate followed
by a clutch disc until entire clutch pack is installed
(4 discs and 3 plates are required) (Fig. 223).
(13) Install the reaction plate.
(14) Install selective snap-ring. Be sure snap-ring
is fully seated in retainer groove.
(15) Using a suitable gauge bar and dial indicator,
measure clutch pack clearance (Fig. 225).
(a) Position gauge bar across the clutch drum
with the dial indicator pointer on the pressure
plate (Fig. 225).
(b) Using two small screw drivers, lift the pres-
sure plate and release it.
(c) Zero the dial indicator.
(d) Lift the pressure plate until it contacts the
snap-ring and record the dial indicator reading.
Clearance should be 0.635 - 0.914 mm (0.025 - 0.036
in.). If clearance is incorrect, steel plates, discs, selective
snap ring and pressure plates may have to be changed.
The selective snap ring thicknesses are:
²0.107 - 0.109 in.
²0.098 - 0.100 in.
²0.095 - 0.097 in.
²0.083 - 0.085 in.
²0.076 - 0.078 in.
²0.071 - 0.073 in.
²0.060 - 0.062 in.
(16) Coat rear clutch thrust washer with petro-
leum jelly and install washer over input shaft and
into clutch retainer (Fig. 226). Use enough petroleum
jelly to hold washer in place.
(17) Set rear clutch aside for installation during
final assembly.
Fig. 224 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAMFig. 225 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4-STAND
5 - REAR CLUTCH
6 - GAUGE BAR
Fig. 226 Installing Rear Clutch Thrust Washer
1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER
21 - 206 AUTOMATIC TRANSMISSION - 46REBR/BE
REAR CLUTCH (Continued)

REAR SERVO
DESCRIPTION
The rear (low/reverse) servo consists of a single
stage or diameter piston and a spring loaded plug.
The spring is used to cushion the application of the
rear (low/reverse) band.
OPERATION
While in the de-energized state (no pressure
applied), the piston is held up in its bore by the pis-
ton spring. The plug is held down in its bore, in the
piston, by the plug spring. When pressure is applied
to the top of the piston, the plug is forced down in its
bore, taking up any clearance. As the piston moves, it
causes the plug spring to compress, and the piston
moves down over the plug. The piston continues to
move down until it hits the shoulder of the plug and
fully applies the band. The period of time from the
initial application, until the piston is against the
shoulder of the plug, represents a reduced shocking
of the band that cushions the shift.
DISASSEMBLY
(1) Remove small snap-ring and remove plug and
spring from servo piston (Fig. 227).
(2) Remove and discard servo piston seal ring.
CLEANING
Remove and discard the servo piston seal ring (Fig.
228). Then clean the servo components with solvent
and dry with compressed air. Replace either spring if
collapsed, distorted or broken. Replace the plug and
piston if cracked, bent, or worn. Discard the servo
snap-rings and use new ones at assembly.
ASSEMBLY
(1) Lubricate piston and guide seals (Fig. 229)
with petroleum jelly. Lubricate other servo parts with
MopartATF +4, type 9602, transmission fluid.
(2) Install new seal ring on servo piston.
(3) Assemble piston, plug, spring and new snap-
ring.
(4) Lubricate piston seal lip with petroleum jelly.
Fig. 227 Rear Servo Components
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
Fig. 228 Rear Servo Components
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
Fig. 229 Rear Servo Components
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 207