engine DODGE RAM 2002 Service Repair Manual

ADAPTER HOUSING SEAL -
NV4500
REMOVAL
(1) Raise and support vehicle.
(2) Mark the propeller shafts and yokes for instal-
lation reference and remove the shafts.
(3) Support transmission with a transmission jack.
(4) Remove engine rear support.
(5) Remove transfer case.
(6) Remove adapter housing seal with a pry tool or
slide hammer mounted screw (Fig. 128).
INSTALLATION
(1) Install adapter housing seal with Installer
C-3860-A and Handle C-4171.
(2) Install transfer case.
(3) Install propeller shafts with reference marks
aligned.
(4) Fill transfer case and transmission to proper
level.
(5) Remove support and lower vehicle.
EXTENSION HOUSING SEAL -
NV4500
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the propeller shaft and yoke for installa-
tion reference.
(3) Remove the propeller shaft.
(4) Remove extension housing seal (Fig. 129) using
Remover C-3985-B.(5) On heavy duty 4X2 vehicles, remove extension
housing seal with a pry tool or a slide hammer
mounted screw.
(6) On light duty transmissions, remove the exten-
sion housing bushing with Remover 6957.
(7) On heavy duty transmissions, remove the
extension housing bushing with Remover 8155.
INSTALLATION
(1) Install housing bushing with Handle C-4171
(Fig. 130) and Installer.
²Light Duty - Installer 6951
²Heavy Duty - Installer 8161
(2) Install housing seal with Handle C-4171 (Fig.
131) and Installer.
²Light Duty - Installer C-3972-A
²Heavy Duty - Installer 8154
(3) Install propeller shaft with reference marks
aligned.
Fig. 128 Adapter Housing - 4WD
1 - ADAPTER HOUSING
2 - SEAL
Fig. 129 Extension Housing - 2WD
1 - EXTENSION HOUSING
2 - SEAL
Fig. 130 Extension Housing Bushing
1 - HANDLE C-4171
2 - INSTALLER
3 - EXTENSION HOUSING
21 - 42 MANUAL - NV4500BR/BE

TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears generate a mild
whine that is audible, but generally only at extreme
speeds. Severe highly audible transmission noise is
generally the initial indicator of a lubricant problem.
Insufficient, improper or contaminated lubricant
will promote rapid wear of gears, synchros, shift
rails, forks and bearings. The overheating caused by
a lubricant problem, can also lead to gear breakage.
REMOVAL
NOTE: Use a heavy duty scissors style transmis-
sion jack for remove of the transmission.
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(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 and isolator plate from
the transmission gear case.
(6) Raise and support vehicle.
(7) Remove skid plate, if equipped.
(8) Mark propeller shaft/shafts and axle yokes for
installation reference.
(9) Remove propeller shaft.
(10) Disconnect and remove exhaust system as
necessary.
(11) Disconnect wires at backup light switch.
(12) Support engine with adjustable safety stand
and wood block.
(13) If transmission is to be disassembled for
repair, remove drain bolt at bottom of PTO cover and
drain lubricant from transmission (Fig. 4).(14) Remove clutch slave cylinder splash shield, if
equipped.
(15) Remove clutch slave cylinder bolts and move
cylinder aside for clearance.
(16) Remove wire harness from clips on transmis-
sion.
TWO WHEEL DRIVE
(1) Remove bolts/nuts mounting transmission to
the rear mount.
(2) Support and secure transmission with safety
chains to a transmission jack.
(3) Remove rear crossmember.
(4) Remove transmission clutch housing bolts at
the engine block.
(5) Slide transmission and jack rearward until
input shaft clears clutch disc and pressure plate.
(6) Lower transmission jack and remove transmis-
sion from under vehicle.
FOUR WHEEL DRIVE
(1) Disconnect transfer case shift linkage at trans-
fer case range lever.
(2) Support and secure transfer case with safety
chains to a transmission jack.
(3) Remove transfer case mounting nuts.
(4) Move transfer case rearward until input gear
clears transmission mainshaft.
(5) Lower transfer case assembly and move it from
under vehicle.
(6) Support and secure transmission with safety
chains to a transmission jack.
(7) Remove bolts/nuts attaching transmission
mount to rear crossmember.
(8) Remove rear crossmember.
(9) Remove transmission clutch housing bolts at
the engine block.
(10) Move transmission rearward until input shaft
clears clutch disc.
(11) Lower transmission and remove it from under
vehicle.
DISASSEMBLY
NOTE: Use Fixture 8241 for moving and handling
the transmission. The fixture supports the transmis-
sion at the center of gravity in order to ease mount-
ing the transmission into the build fixture.
(1) Mount the transmission into Fixture 8230 (Fig.
5).
(2) Rotate the transmission to the horizontal posi-
tion, if necessary.
Fig. 4 NV5600 Drain Bolt
1 - PTO COVER
2 - DRAIN BOLT
BR/BEMANUAL - NV5600 21 - 49
MANUAL - NV5600 (Continued)

(4) Install Fixture 8232 to the transmission gear
case.
(5) Attach an engine crane or equivalent to Fixture
8232 and remove the transmission gear case from the
clutch housing (Fig. 27).(6) Remove rear output shaft and countershaft
bearing races from the transmission gear case with a
brass drift and hammer.
GEARTRAIN
(1) Remove bolts holding the 5-6 crossover bracket
to the clutch housing (Fig. 28).
(2) Attach Fixture 8232 to the output shaft and
countershaft (Fig. 29).
Fig. 25 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
Fig. 26 REVERSE SHIFT FORK
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 27 TRANSMISSION LIFT
1 - FIXTURE
2 - TRANSMISSION CASE
Fig. 28 5-6 CROSSOVER
1 - 5-6 CROSSOVER BRACKET
BR/BEMANUAL - NV5600 21 - 55
MANUAL - NV5600 (Continued)

(3) Attach an engine crane or equivalent to Fixture
8232 and raise the geartrain approximately 1/4 in.
from the clutch housing.
(4) Remove 5-6 crossover bracket from the clutch
housing.
(5) Lower the geartrain back into the clutch hous-
ing.
(6) Install Holding Tool 8242 (Fig. 30) onto the 5-6
synchro and tighten the screw to hold the 5-6 syn-
chro together during the removal operation.
NOTE: Note the order of the shift fork arms at the
primary shift rail, while in the Neutral position.
(7) Raise geartrain and shift rails until all the
shift rails clear the clutch housing.
(8) Remove shift rails from the rest of the
geartrain (Fig. 31).
(9) Raise the geartrain until the input shaft is
clear of the clutch housing.
(10) Remove geartrain from the clutch housing and
install the geartrain into Support Stand 8246 (Fig.
32).
(11) Remove Fixture 8232 from the output shaft
and the countershaft.(12) Separate the countershaft from the output
shaft.
Fig. 29 ATTACH FIXTURE
1 - FIXTURE
Fig. 30 HOLDING TOOL
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
Fig. 31 SHIFT RAILS
1 - 5-6 SHIFT RAIL
21 - 56 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(13) Separate the output shaft from the input
shaft. Hold the 5-6 synchro together while removing
the output shaft to prevent the synchro sleeve from
being dislodged from the synchro hub.
COUNTERSHAFT BEARINGS
(1) Remove snap-ring holding the front counter-
shaft bearing onto the countershaft.
(2) Remove front countershaft bearing with Sleeve
6444-8, Adapters 6451, Puller Rods 6444-4 and Puller
6444 (Fig. 33).
(3) Remove rear countershaft bearing with Sleeve
6444-8, Adapters 6447, Puller Rods 6444-4, Puller
6444 and suitable press button (Fig. 34).
OUTPUT SHAFT BEARINGS
(1) Remove snap-ring holding the pocket bearing
onto the output shaft.
(2) Remove pocket bearing from the output shaft
with Sleeve 6444-8, Adapters 8234, Puller Rods
6444-4 and the remainder of Puller 6444 (Fig. 35).
(3) Remove snap-ring holding the rear output shaft
bearing onto the output shaft.
(4) Use Sleeve 6444-8, Adapters 8271 and Puller
Rods 6444-3 for 4X2 vehicles or Puller Rods 6444-4
for 4X4 vehicles with the remainder of Puller 6444 to
remove the rear output shaft bearing from the output
shaft.
(5) Remove rear output shaft thrust washer from
the output shaft.
Fig. 32 LIFT GEARTRAIN WITH ENGINE CRANE
1 - FIXTURE
2 - SUPPORT STAND
Fig. 33 FRONT COUNTERSHAFT BEARING
1 - PULLER
2 - ADAPTERS
Fig. 34 REAR COUNTERSHAFT BEARING
1 - PULLER
2 - ADAPTERS
BR/BEMANUAL - NV5600 21 - 57
MANUAL - NV5600 (Continued)

GEARTRAIN
(1) Install input shaft into Support Stand 8246.
(2) Install fifth gear friction cone onto the input
shaft.
(3) Install fifth gear blocker ring onto the fifth
gear friction cone.
(4) Install output shaft into the input shaft (Fig.
79).
(5) Install countershaft into the Support Stand
8246 and verify that all gears are meshed with their
mates on the mainshaft (Fig. 80).
(6) Install Fixture 8232 to the output shaft and
countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro
and tighten the screw to hold the 5-6 synchro
together during the remainder of the installation pro-
cedure.
(8) Attach a engine crane or equivalent to Fixture
8232 and move the geartrain from the Support Stand
8246 to the clutch housing (Fig. 81).
(9) Install shift forks and rails onto the geartrain
(Fig. 82).NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.
(10) Install geartrain and shift rails into the clutch
housing. Lower the geartrain and rails into the hous-
ing slowly while guiding input shaft through input
shaft seal. Avoid any binds on the shift rails, forks
and synchros as the rails enter their bushings.
CAUTION: Do not damage input shaft seal with the
input shaft splines.
(11) With the geartrain approximately 1/4 in. from
the clutch housing, remove Holding Tool 8242 from
the 5-6 synchro (Fig. 83).
(12) Install 5-6 crossover bracket and arm to the
shift rails and the clutch housing.
(13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts and
tighten to 28 N´m (20 ft. lbs.) (Fig. 84).
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
Fig. 79 OUTPUT SHAFT AND INPUT SHAFT
1 - OUTPUT SHAFT
2 - INPUT SHAFT
3 - SUPPORT STAND
Fig. 80 COUNTERSHAFT TO MAINSHAFT
1 - COUNTERSHAFT
2 - OUTPUT SHAFT
3 - SUPPORT STAND
21 - 72 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(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)

(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)

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

IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas-
ket surface (Fig. 2). Refer to this information when
ordering replacement parts.
GEAR RATIOS
The 46RE gear ratios are:
1st.................................2.45:1
2nd................................1.45:1
3rd.................................1.00:1
4th.................................0.69:1
Rev..................................2.21
OPERATION
The application of each driving or holding compo-
nent is controlled by the valve body based upon the
manual lever position, throttle pressure, and gover-
nor pressure. The governor pressure is a variable
pressure input to the valve body and is one of the
signals that a shift is necessary. First through fourth
gear are obtained by selectively applying and releas-
ing the different clutches and bands. Engine power is
thereby routed to the various planetary gear assem-
blies which combine with the overrunning clutch
assemblies to generate the different gear ratios. The
torque converter clutch is hydraulically applied and
is released when fluid is vented from the hydraulic
circuit by the torque converter control (TCC) solenoid
on the valve body. The torque converter clutch is con-
trolled by the Powertrain Control Module (PCM). The
torque converter clutch engages in fourth gear, and
in third gear under various conditions, such as when
the O/D switch is OFF, when the vehicle is cruising
on a level surface after the vehicle has warmed up.
The torque converter clutch will disengage momen-
tarily when an increase in engine load is sensed by
the PCM, such as when the vehicle begins to go
uphill or the throttle pressure is increased. The
torque converter clutch feature increases fuel econ-
omy and reduces the transmission fluid temperature.
Since the overdrive clutch is applied in fourth gear
only and the direct clutch is applied in all ranges
except fourth gear, the transmission operation for
park, neutral, and first through third gear will be
described first. Once these powerflows are described,
the third to fourth shift sequence will be described.
1 - TORQUE CONVERTER 11 - DIRECT CLUTCH
2 - INPUT SHAFT 12 - PLANETARY GEAR
3 - OIL PUMP 13 - OUTPUT SHAFT
4 - FRONT BAND 14 - SEAL
5 - FRONT CLUTCH 15 - INTERMEDIATE SHAFT
6 - REAR CLUTCH 16 - OVERDRIVE OVERRUNNING CLUTCH
7 - PLANETARIES 17 - DIRECT CLUTCH SPRING
8 - REAR BAND 18 - OVERDRIVE PISTON RETAINER
9 - OVERRUNNING CLUTCH 19 - FILTER
10 - OVERDRIVE CLUTCH 20 - VALVE BODY
Fig. 2 Transmission Part And Serial Number
Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 91
AUTOMATIC TRANSMISSION - 46RE (Continued)