transmission DODGE RAM 2002 Service Repair Manual

(4) Apply sealant to the clutch housing.
(5) Attach an engine crane or equivalent to Fixture
8232 and install the transmission gear case onto the
clutch housing (Fig. 85).
(6) Install clutch housing bolts and tighten to 48
N´m (35 ft.lbs.).
(7) Install shift socket roll pin with a suitable
6mm (7/32 inch) punch and hammer.
MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) With transmission in vertical position, use
Socket 6993 to rotate the shafts and seat the bear-
ings.
(2) Measure mainshaft endplay with Dial Indicator
Set C-3339 and Extension Rod 8161 installed onto
the rear of the transmission gear case (Fig. 86).
(3) Measure countershaft end-play with Dial Indi-
cator Set C-3339 and Extension Rod 8161 installed
onto the rear of the transmission gear case (Fig. 87).
(4) Rotate transmission into a horizontal position
and remove the input shaft retainer.
(5) Install shims necessary to achieve an end-play
of 0.051-0.15 mm (0.002-0.006 in.) for the mainshaft
and countershaft.
NOTE: Countershaft shims go between the bearing
race and spacer. Mainshaft shims go into the input
shaft retainer.
(6) Install anewinput shaft seal into the input
shaft retainer with Installer C-4965.
Fig. 85 TRANSMISSION GEAR CASE
1 - FIXTURE
2 - TRANSMISSION CASE
Fig. 86 MAINSHAFT END-PLAY
1 - DIAL INDICATOR
2 - EXTENSION ROD
3 - MAIN SHAFT
Fig. 87 COUNTERSHAFT END-PLAY
1 - EXTENSION ROD
2 - DIAL INDICATOR
3 - COUNTERSHAFT
21 - 74 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install the crossover cam bushing into the
extension/adapter housing with Installer 8239 and
Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 94).
(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
Fig. 90 REVERSE GEAR COMPONENTS
1 - REVERSE GEAR
2 - REVERSE BEARING
3 - BLOCKER RING
4 - FRICTION CONE
Fig. 91 OUTPUT SHAFT BEARING AND THRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
Fig. 92 REVERSE IDLER AND COUNTERSHAFT
GEARS
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT REVERSE GEAR
Fig. 93 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
21 - 76 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(10) Place Gauge Bar 6311 across the housing face.
Measure the distance from the top of the bar to the
bottom of the reverse countershaft bearing race bore
(Fig. 95).(11) Subtract thickness of the gauge bar from the
measurement and record the result.
(12) The difference between the two measurements
is the end-play for the reverse countershaft gear
assembly.
(13) Install shims to achieve 0.15-0.25 mm (0.006-
0.010 in.) end-play for the reverse countershaft gear
assembly into the reverse countershaft bearing race
bore.
(14) Use Installer to install the reverse counter-
shaft bearing race into the extension/adapter hous-
ing.
(15) Install back-up lamp switch into the exten-
sion/adapter housing and tighten to 28 N´m (20
ft.lbs.).
(16) Install crossover cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 96).
(18) Install crossover detent plunger, spring and
plug into the extension/adapter housing. Tighten the
plug to 47.5 N´m (35 ft.lbs.) (Fig. 97).
(19) Apply sealer to the surface of the transmis-
sion case.
(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter
housing onto the transmission gear case. Tighten
bolts to 48 N´m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N´m (41 ft.lbs.).
(23) Install primary shift rail detent plunger,
spring and plug into the transmission case. Tighten
detent plug to 47.5 N´m (35 ft.lbs.).
Fig. 94 MEASURE HEIGHT OF REVERSE
COUNTERSHAFT
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
Fig. 95 REVERSE COUNTERSHAFT GEAR BEARING
RACE BORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
Fig. 96 CROSSOVER CAM
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
BR/BEMANUAL - NV5600 21 - 77
MANUAL - NV5600 (Continued)

(24) Install shift tower onto the transmission case
and tighten bolts to 9 N´m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all com-
ponents supplied with the transmission. If a new
shift tower is supplied with the new transmission,
do not re-use the original shift tower.
(1) Apply a light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces of
following components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission under vehicle.
(4) Raise transmission until input shaft is centered
in clutch disc hub.
(5) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(6) Work transmission forward until seated against
engine block. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install and tighten transmission-to-engine
block bolts.
(8) Install clutch slave cylinder.
(9) Connect backup light switch wires.
(10) Position transmission harness wires in clips
on transmission.(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Fill transmission with required lubricant (Fig.
98). Check lubricant level in transfer case if
equipped.
TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components.
(3) Remove support and lower vehicle.
(4) Shift transmission into third gear.
(5) Clean the mating surfaces of shift tower and
isolator plate with suitable wax and grease remover.
(6) Apply Mopar Gasket Maker or equivalent to
sealing surface of the transmission case. Do not over
apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(9) Verify shift tower, isolator plate and the shift
socket are properly aligned.
(10) Install bolts to hold the shift tower to the iso-
lator plate and the transmission case. Tighten bolts
to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install and secure transfer case on the trans-
mission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
Fig. 97 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
Fig. 98 FILL PLUG
1 - FILL PLUG
21 - 78 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(3) Move transfer case forward and seat it on
adapter.
(4) Install and tighten transfer case mounting nuts
to 41-47 N´m (30-35 ft. lbs.) if case has 3/8 studs. If
case has 5/16 studs tighten to 30-41 N´m (22-30 ft.
lbs.).
(5) Connect transfer case shift lever to range lever
on transfer case.
(6) Install propeller shafts with reference marks
aligned.
(7) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(8) Install exhaust system components.
(9) Remove support and lower vehicle.
(10) Shift transmission into third gear.
(11) Clean the mating surfaces of shift tower, iso-
lator plate and transmission case with suitable wax
and grease remover.(12) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission case. Do not
over apply sealant.
(13) Install isolator plate onto the transmission
case, metal side down.
(14) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(15) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(16) Install the bolts to hold the shift tower to the
isolator plate and the transmission case. Tighten the
shift tower bolts to 10.2-11.25 N´m (7.5-8.3 ft. lbs.).
(17) Install shift lever boot and bezel.
(18) Connect battery negative cable.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Crossover Cam and
Detent48 35 -
Bolt, Input Retainer 28 20 -
Bolt, 5-6 Crossover
Bracket28 20 -
Bolt, Clutch Housing 48 35 -
Bolt, Extension/Adapter
Housing48 35 -
Bolt, Shift Tower 9 7 80
Switch, Back-up Lamp 28 20 -
Bolt, Shift Blocker 55 41 -
Bolt, PTO Cover 40 30 -
Pivot, Clutch Release
Lever22 16 -
Plug, Fill 30 22 -
Nut, Output Shaft 339 250 -
BR/BEMANUAL - NV5600 21 - 79
MANUAL - NV5600 (Continued)

ADAPTER HOUSING SEAL -
NV5600
REMOVAL
(1) Raise and support vehicle.
(2) Mark propeller shaft and yokes for installation
reference and remove shaft.
(3) Remove the transfer case.
(4) Remove the adapter housing seal with a pry
tool or slide hammer with a screw.
INSTALLATION
(1) Install adapter housing seal with Installer and
Handle C-4171.
(2) Install transfer case.
(3) Install propeller shaft with reference marks
aligned.
(4) Check fluid level.
(5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL -
NV5600
REMOVAL
(1) Raise and support vehicle.
(2) Mark propeller shaft and pinion yoke for
installation reference and remove the propeller shaft.
(3) Remove extension housing seal with a pry tool
or a slide hammer and screw.
(4) Remove extension housing bushing with
Remover 8155 (Fig. 99).
INSTALLATION
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171 (Fig. 100).
(2) Install extension housing seal with Installer
8154 and Handle C-4171 (Fig. 101).
(3) Install propeller shaft with reference marks
aligned.
(4) Check and fill transmission.
(5) Remove support and lower vehicle.
Fig. 99 EXTENSION HOUSING
1 - REMOVER
Fig. 100 EXTENSION HOUSING BUSHING
1 - HANDLE
2 - INSTALLER
3 - BUSHING
Fig. 101 EXTENSION HOUSING SEAL
1 - INSTALLER
2 - HANDLE
BR/BEMANUAL - NV5600 21 - 85

SHIFT COVER - NV5600
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(5) Remove the shift tower (Fig. 102) and isolator
plate (Fig. 103) from the transmission.
INSTALLATION
(1) Shift transmission into third gear.(2) Clean the mating surfaces of shift tower, isola-
tor plate and transmission gear case with suitable
wax and grease remover.
(3) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission. Do not over
apply sealant.
(4) Install isolator plate onto the transmission,
metal side down.
(5) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and iso-
lator plate.
(6) Verify shift tower, isolator plate and shift tower
bushings are properly aligned.
(7) Install shift tower bolts and tighten the shift
tower bolts to 8-10 N´m (7-9 ft. lbs.).
(8) Install shift lever extension, shift boot and
bezel.
Fig. 102 SHIFT TOWER
1 - SHIFT TOWER
2 - TRANSMISSION
Fig. 103 SHIFT TOWER ISOLATOR PLATE
1 - ISOLATOR PLATE
2 - TRANSMISSION
21 - 86 MANUAL - NV5600BR/BE

AUTOMATIC TRANSMISSION - 46RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 46RE
DESCRIPTION.........................89
OPERATION...........................91
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION......................96
DIAGNOSIS AND TESTING - PRELIMINARY . 97
DIAGNOSIS AND TESTING - ROAD
TESTING............................97
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST.....................98
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION........................100
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................101
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS...........................102
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................114
REMOVAL............................114
DISASSEMBLY........................115
CLEANING...........................122
INSPECTION.........................122
ASSEMBLY...........................122
INSTALLATION........................130
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............132
SPECIFICATIONS
TRANSMISSION.....................144
SPECIAL TOOLS
RE TRANSMISSION..................146
ACCUMULATOR
DESCRIPTION........................149
OPERATION..........................150
INSPECTION.........................150
BANDS
DESCRIPTION........................150
OPERATION..........................151
ADJUSTMENTS
ADJUSTMENT - BANDS...............151
ELECTRONIC GOVERNOR
DESCRIPTION........................152
OPERATION..........................153
REMOVAL............................154
INSTALLATION........................154
EXTENSION HOUSING BUSHING
REMOVAL............................156
INSTALLATION........................156EXTENSION HOUSING SEAL
REMOVAL............................156
INSTALLATION........................156
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............157
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................157
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................157
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................157
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............158
STANDARD PROCEDURE - TRANSMISSION
FILL...............................160
FRONT CLUTCH
DESCRIPTION........................160
OPERATION..........................160
DISASSEMBLY........................161
INSPECTION.........................162
ASSEMBLY...........................162
FRONT SERVO
DESCRIPTION........................164
OPERATION..........................164
DISASSEMBLY........................164
CLEANING...........................164
INSPECTION.........................164
ASSEMBLY...........................164
OIL PUMP
DESCRIPTION........................166
OPERATION..........................166
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK.....................166
DISASSEMBLY........................167
CLEANING...........................168
INSPECTION.........................168
ASSEMBLY...........................169
OUTPUT SHAFT FRONT BEARING
REMOVAL............................171
INSTALLATION........................171
OUTPUT SHAFT REAR BEARING
REMOVAL............................171
INSTALLATION........................172
OVERDRIVE CLUTCH
DESCRIPTION........................172
OPERATION..........................172
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 87

OVERDRIVE UNIT
REMOVAL............................173
DISASSEMBLY........................173
CLEANING...........................179
INSPECTION.........................180
ASSEMBLY...........................180
INSTALLATION........................189
OVERDRIVE SWITCH
DESCRIPTION........................190
OPERATION..........................190
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS..............191
REMOVAL............................191
INSTALLATION........................191
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION........................192
OPERATION..........................192
DISASSEMBLY........................192
CLEANING...........................192
INSPECTION.........................193
ASSEMBLY...........................193
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING - PARK/NEUTRAL
POSITION SWITCH...................195
REMOVAL............................195
INSTALLATION........................195
PISTONS
DESCRIPTION........................195
OPERATION..........................196
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION........................197
OPERATION..........................197
DISASSEMBLY........................198
INSPECTION.........................199
ASSEMBLY...........................199
REAR CLUTCH
DESCRIPTION........................203
OPERATION..........................203
DISASSEMBLY........................204
CLEANING...........................204
INSPECTION.........................204
ASSEMBLY...........................205
REAR SERVO
DESCRIPTION........................207OPERATION..........................207
DISASSEMBLY........................207
CLEANING...........................207
ASSEMBLY...........................207
SHIFT MECHANISM
DESCRIPTION........................208
OPERATION..........................208
ADJUSTMENTS
ADJUSTMENT.......................208
SOLENOID
DESCRIPTION........................208
OPERATION..........................209
SPEED SENSOR
DESCRIPTION........................209
OPERATION..........................209
THROTTLE VALVE CABLE
DESCRIPTION........................209
ADJUSTMENTS - TRANSMISSION THROTTLE
VALVE CABLE.......................210
TORQUE CONVERTER
DESCRIPTION........................212
OPERATION..........................215
REMOVAL............................216
INSTALLATION........................217
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION........................217
OPERATION..........................217
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE........217
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION........................218
OPERATION..........................218
VALVE BODY
DESCRIPTION........................218
OPERATION..........................223
REMOVAL............................236
DISASSEMBLY........................237
CLEANING...........................244
INSPECTION.........................244
ASSEMBLY...........................248
INSTALLATION........................256
ADJUSTMENTS - VALVE BODY...........257
21 - 88 AUTOMATIC TRANSMISSION - 46REBR/BE

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 the
low/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.
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 89