air filter DODGE RAM 2002 Service Manual PDF

The machined tapers on both injection pump
shaft and injection pump gear (Fig. 42) must be
absolutely dry, clean and free of any dirt or oil
film. This will ensure proper gear-to-shaft tight-
ening.
(5) Clean pump gear and pump shaft at machined
tapers (Fig. 42) with an evaporative type cleaner
such as brake cleaner.
Keyway Installation:
(6) The pump/gear keyway has an arrow and a
3±digit number stamped at top edge (Fig. 41). Posi-
tion keyway into pump shaft witharrow pointed to
rear of pump.Also be sure 3±digit number stamped
to top of keyway is same as 3±digit number stamped
to injection pump data plate (Fig. 43). If wrong key-
way is installed, a diagnostic trouble code may be
set.
(7) Position pump assembly to mounting flange on
gear cover while aligning injection pump shaft
through back of injection pump gear. When installing
pump, dowel (Fig. 42) on mounting flange must align
to hole in front of pump.(8) After pump is positioned flat to mounting
flange, install four pump mounting nuts and tighten
finger tight only. Do not attempt a final tightening at
this time.Do not attempt to tighten (pull) pump
to gear cover using mounting nuts. Damage to
pump or gear cover may occur. The pump must
be positioned flat to its mounting flange before
attempting to tighten mounting nuts.
(9) To prevent damage or cracking of components,
tighten nuts/bolts in the following sequence:
(a) Install injection pump shaft washer and nut
to pump shaft. Tighten nutfinger tight only.
(b) Install 2 rear/lower pump mounting bolts
finger tight only.
(c) Do preliminary tightening of injection pump
shaft nut to 30 N´m (15±22 ft. lbs.) torque.This is
not the final torque.
(d) Tighten 4 pump mounting nuts to 43 N´m
(32 ft. lbs.) torque.
(e) Tighten 2 rear/lower pump bracket-to-pump
bolts 24 N´m (18 ft. lbs.) torque.
(f) Do final tightening of injection pump shaft
nut to 170 N´m (125 ft. lbs.) torque. Use barring
tool to prevent engine from rotating when tighten-
ing gear.
(10) Install canister (Fig. 33) to gear cover.
(11) Install crankcase vent hose (Fig. 33) to canis-
ter and install hose clamp.
(12) Using new gaskets, install fuel return line
and overflow valve to side of injection pump (Fig. 32).
Tighten overflow valve to 24 N´m (18 ft. lbs.) torque.
(13) Using new gaskets, install fuel supply line to
side of injection pump and top of fuel filter housing
(Fig. 32). Tighten banjo bolts to 24 N´m (18 ft. lbs.)
torque.
(14) Install all high-pressure fuel lines, intake air
tube, accelerator pedal position sensor, air intake
housing, engine oil dipstick tube, wiring clips, electri-
cal cables at intake heaters and engine lifting
bracket. Refer to High-Pressure Fuel Line Removal/
Installation. All of these items are covered in this
procedure.
(15) Connect 9±way electrical connector to Fuel
Pump Control Module (FPCM) (Fig. 31).
(16) Connect both negative battery cables to both
batteries.
(17) Bleed air from fuel system.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(18) Check system for fuel or engine oil leaks.
Fig. 43 Injection Pump Data Plate Location
1 - PUMP DATA PLATE
14 - 76 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

CAUTION: Be sure that the high-pressure fuel lines
are installed in the same order that they were
removed.
(1) Lubricate threads of injector line fittings with
clean engine oil.
(2) Loosen, but do not remove, all fuel line support
bracket bolts.
(3) Installrearinjection line bundle beginning
with cylinder head (fuel injector) connections, fol-
lowed by injection pump connections. Tighten all fit-
tings finger tight.
(4) Tighten fittings at fuel injector ends for cylin-
ders number 6 and 5 to 38 N´m (28 ft. lbs.) torque.
Do not tighten number 3 line at this time. It
will be tightened during bleeding procedure.
(5) Tighten 3 fittings at fuel injection pump ends
to 24 N´m (18 ft. lbs.) torque.
(6) Installfrontinjection line bundle beginning
with cylinder head (fuel injector) connections, fol-
lowed by injection pump connections. Tighten all fit-
tings finger tight.
(7) Tighten fitting at fuel injector end for cylinder
number 2 to 38 N´m (28 ft. lbs.) torque.Do not
tighten lines number 1 or 4 at this time. They
will be tightened during bleeding procedure.
(8) Tighten remaining 3 fittings at fuel injection
pump ends to 24 N´m (18 ft. lbs.) torque.
(9) Install fuel line support bracket bolts to intake
manifold and tighten to 24 N´m (18 ft. lbs.) torque.
CAUTION: Be sure fuel lines are not contacting
each other or any other component. Noise will
result.
(10) Install engine lifting bracket at rear of intake
manifold. Tighten 2 bolts to 77 N´m (57 ft. lbs.)
torque.
(11) Install cable bracket housing/cable assembly
and tighten 3 mounting bolts to 24 N´m (18 ft. lbs.)
torque.
(12) Clean any old gasket material below and
above intake manifold air heater element block. Also
clean mating areas at intake manifold and air intake
housing.
(13) Using new gaskets, position intake manifold
air heater element block to engine.
(14) Install air intake housing and position ground
cable. Install 4 mounting bolts and tighten to 24 N´m
(18 ft. lbs.) torque.
(15) Install air tube (intake manifold-to-charge air
cooler) (Fig. 49). Tighten clamps to 8 N´m (72 in. lbs.)
torque.
(16) Install engine oil dipstick tube support mount-
ing bolt and tighten to 24 N´m (18 ft. lbs.) torque.
(17) Install engine oil dipstick to engine.(18) Connect 2 electrical cables to cable mounting
studs.
(19) Connect electrical connector to bottom of
APPS by pushing connector upward until it snaps
into position.
(20) Connect wiring harness (clip) at bottom of
Accelerator Pedal Position Sensor (APPS) mounting
bracket (Fig. 48).
(21) Connect front wiring clip (Fig. 49) to cable
bracket housing.
(22) Install cable cover (Fig. 47).
(23) Connect both negative battery cables to both
batteries.
(24) Bleed air from fuel system. Do this at fuel
injector ends of lines. Use cylinders numbers 1, 3 and
4 for bleeding. (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE). After
bleeding, tighten fittings to 38 N´m (28 ft. lbs.)
torque.
(25) Check lines/fittings for leaks.
FUEL TANK
DESCRIPTION - DIESEL FUEL TANK
The fuel tank is similar to the tank used with gas-
oline powered models. The tank is equipped with a
separate fuel return line and a different fuel tank
module for diesel powered models. A fuel tank
mounted, electric fuel pump is not used with diesel
powered models. Refer to Fuel Tank Module for addi-
tional information.
For removal and installation procedures, refer to
Fuel Tank - Gasoline Engines.
FUEL TANK MODULE
DESCRIPTION
An electric fuel pump isnot usedin the fuel tank
module for diesel powered engines. Fuel is supplied
by the engine mounted fuel transfer pump and the
fuel injection pump.
The fuel tank module is installed in the top of the
fuel tank (Fig. 56). The fuel tank module (Fig. 56)
contains the following components:
²Fuel reservoir
²A separate in-tank fuel filter
²Rollover valve
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection
²Fuel return line connection
²Auxiliary non-pressurized fuel supply fitting
OPERATION
Refer to Fuel Gauge Sending Unit.
14 - 82 FUEL DELIVERY - DIESELBR/BE
FUEL LINES (Continued)

(7) Because fuel pump relay was removed, a Diag-
nostic Trouble Code (DTC) may have been set. After
testing is completed, and relay has been installed,
use DRB scan tool to remove DTC.
Fuel Supply Restriction Test:
Due to very small vacuum specifications, the DRB
scan tool along with the Periphal Expansion Port
(PEP) Module and 0±15 psi transducer must be used.
(8) Verify transfer pump pressure is OK before
performing restriction test.
(9) Locate and disconnect fuel supply line quick-
connect fitting at left-rear of engine (Fig. 63). After
disconnecting line, plastic clip will remain attached
to metal fuel line at engine. Carefully remove clip
from metal line. Snap same clip into fuel supply
hose.
(10) Install Special Rubber Adapter Hose Tool
6631 (3/8º) into ends of disconnected fuel supply line.
(11) Install transducer from PEP module to brass
ªTº fitting on tool 6631.
(12) Hook up DRB scan tool to transducer.
WARNING: DO NOT STAND IN LINE WITH THE
COOLING FAN FOR THE FOLLOWING STEPS.
(13) Start engine and record vacuum reading with
engine speed at high-idle (high-idle means engine
speed is at 100 percent throttle and no load). The
fuel restriction testMUSTbe done with engine speed
at high-idle.
(14) If vacuum reading islessthan 6 in/hg. (0±152
mm hg.), test is OK. If vacuum reading ishigher
than 6 in/hg. (152 mm hg.), restriction exists in fuel
supply line or in fuel tank module. Check fuel supply
line for damage, dents or kinking. If OK, remove
module and check module and lines for blockage.
Also check fuel pump inlet filter at bottom of module
for obstructions.
Testing For Air Leaks in Fuel Supply Side:
(15) A 3±foot section of 3/8º I.D. clear tubing is
required for this test.
(16) Using a tire core valve removal tool, carefully
remove core valve from inlet fitting test port.
(17) Attach and clamp the 3/8ºclear hose to fitting
nipple.
(18) Place other end of hose into a large clear con-
tainer. Allow hose to loop as high as possibleabove
test port.
(19) The fuel transfer pump can be put into a 25
second run (test) mode if key is quickly turned to
crank position and released back to run position
without starting engine.
To prevent engine from starting in this test, first
remove fuel system relay (fuel injection pump relay).
Relay is located in Power Distribution Center (PDC).
Refer to label under PDC cover for relay location.
Because fuel pump relay was removed, a DiagnosticTrouble Code (DTC) may have been set. After testing
is completed, and relay has been installed, use DRB
scan tool to remove DTC.
(20) Allow air to purge from empty hose before
examining for air bubbles. Air bubbles should not be
present.
(21) If bubbles are present, check for leaks in sup-
ply line to fuel tank.
(22) If supply line is not leaking, remove fuel tank
module and remove filter at bottom of module (filter
snaps to module). Check for leaks between supply
nipple at top of module, and filter opening at bottom
of module. Replace module if necessary.
(23) After performing test, install core back into
test fitting. Before installing protective cap, be sure
fitting is not leaking.
REMOVAL
The fuel transfer pump (fuel lift pump) is located
on left side of engine, below and rearward of fuel fil-
ter (Fig. 64).
(1) Disconnect both negative battery cables at both
batteries.
Fig. 64 Fuel Transfer Pump Location
1 - OIL PRESSURE SENSOR
2 - PUMP BRACKET NUTS (3)
3 - SUPPORT BRACKET BOLT
4 - BANJO BOLT (REAR)
5 - FUEL SUPPLY LINE
6 - ELECTRICAL CONNECTOR
7 - BANJO BOLT (FRONT)
8 - FUEL TRANSFER PUMP
14 - 86 FUEL DELIVERY - DIESELBR/BE
FUEL TRANSFER PUMP (Continued)

WATER IN FUEL SENSOR
DESCRIPTION
The WIF sensor is located on the side of the fuel
filter/water separator canister (Fig. 68).
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the
side of fuel filter/water separator canister. Refer to
Fuel Filter/Water Separator Removal/Installation for
WIF sensor removal/installation procedures.
FUEL DRAIN MANIFOLD
DESCRIPTION
The fuel drain manifold is actually a rifled passage
within the cylinder head (Fig. 69).
OPERATION
When the engine is running, and during injection,
a small amount of fuel flows past the injector nozzle
and is not injected into the combustion chamber. This
fuel is used to lubricate the fuel injectors. Excess fuel
drains into the fuel drain manifold (or passage). Fuel
is drained from this passage into a line at the rear of
the cylinder head (Fig. 69). After exiting the cylinder
head, fuel is routed (returned) back to the fuel tank.
A ªTº is installed into the fuel return line (Fig. 69).
This ªTº is used to allow excess fuel from the injec-
tion pump to be returned into the fuel tank. A one-
way check valve within the overflow valve prevents
fuel (from the fuel drain manifold) from entering the
fuel injection pump.
Asmallamount of fuel is returned from the fuel
injectors, while alargeamount (about 70% of sup-
plied fuel) is returned from the fuel injection pump.
Fig. 68 Water-in-Fuel Sensor Location
1 - WATER-IN-FUEL (WIF) SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - WIF SENSOR CONNECTOR
Fig. 69 Fuel Drain Manifold Passage
1 - REAR OF CYLINDER HEAD
2 - BANJO FITTING/BOLT
3 - FUEL RETURN TO TANK
4 - FUEL RETURN LINES
5 - FUEL RETURN LINE FROM PUMP OVERFLOW VALVE
6 - FUEL DRAIN MANIFOLD PASSAGE
7 - ªTº
BR/BEFUEL DELIVERY - DIESEL 14 - 89

Fig. 1 FUEL SYSTEM COMPONENTS - DIESEL
1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR 14 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)
2 - THROTTLE LEVER BELLCRANK AND APPS (ACCELERATOR
PEDAL POSITION SENSOR)15 - FUEL TRANSFER (LIFT) PUMP
3 - INTAKE MANIFOLD AIR HEATER/ELEMENTS 16 - OIL PRESSURE SENSOR
4 - HIGH-PRESSURE FUEL LINES 17 - FUEL FILTER/WATER SEPARATOR
5 - FUEL HEATER 18 - DRAIN TUBE
6 - FUEL PRESSURE TEST PORT 19 - WATER-IN-FUEL (WIF) SENSOR
7 - MAP (BOOST) SENSOR 20 - ENGINE CONTROL MODULE (ECM)
8 - FUEL INJECTORS 21 - FUEL PRESSURE TEST PORT
9 - FUEL INJECTOR CONNECTOR 22 - CAMSHAFT POSITION SENSOR (CMP)
10 - INTAKE AIR TEMPERATURE (IAT) SENSOR 23 - OVERFLOW VALVE
11 - FUEL DRAIN MANIFOLD 24 - FUEL INJECTION PUMP
12 - DRAIN VALVE 25 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT)
13 - FUEL RETURN LINE (TO FUEL TANK)
14 - 92 FUEL INJECTION - DIESELBR/BE
FUEL INJECTION - DIESEL (Continued)

SPECIFICATIONS
TORQUE - DIESEL ENGINE
DESCRIPTION N m Ft. Lbs. In. Lbs.
Accelerator Pedal Position Sensor Bracket Bolts 12 9 105
Air Intake Housing Bolts 24 18 212
Banjo Fittings at top of Filter/Separator 24 18 212
Banjo Fittings at Fuel Return Lines 24 18 212
Banjo Fitting At Fuel Supply Line (Injector Pump) 24 18 212
Camshaft Position Sensor (CMP) Bolt 20 15 177
ECM Mounting Bolts 24 18 212
Engine Coolant Temperature (ECT) Sensor 14 10 124
Engine Lifting Bracket Bolts 77 57 681
Fuel Drain Manifold ªTº Fitting 12 9 106
Fuel Filter Canister Bracket Bolts 24 18 212
Fuel Filter Canister Mounting Nut 14 10 124
Fuel Filter Drain Valve Mounting Screws 3-5 2-4 30-40
Fuel Heater Screws 2-3 1-2 15-20
Fuel Injector Clamp Bolts 10 7 89
Fuel Pump Module Locknut 24-44 18-32 212-389
Fuel Tank Mounting Nuts 41 30 363
Fuel Transfer Pump Mounting Nuts 12 9 106
High-Pressure Fuel Line Fittings (at Injectors) 38 28 336
High-Pressure Fuel Line Fittings (at Pump) 24 18 212
High-Pressure Fuel Line Clamps-to-Intake Manifold 24 18 212
Hose Clamps at Intercooler Tube 8 6 72
Injection Pump-to-Injection Pump Gear Nut 170 125
Injection Pump Mounting Nuts 43 32 380
Intake Manifold Air Temperature (IAT) Sensor 14 10
Intake Manifold Air Heater Relay Bolts 4.5 40
Manifold Air Pressure (MAP) Sensor 14 10
PCM Mounting Bolts 4 35
Overflow Valve-to-Fuel Injection Pump 24 18
Water-In-Fuel (WIF) Sensor 2-3 15-20
14 - 94 FUEL INJECTION - DIESELBR/BE
FUEL INJECTION - DIESEL (Continued)

lines before opening up any fuel system component.
Always cover or cap any open fuel connections before
a fuel system repair is performed.
Each fuel injector connector tube contains an edge
filter (Fig. 13) that breaks up small contaminants
that enter the injector. The edge filter uses the injec-
tors pulsating high-pressure to break up most parti-
cles so they are small enough to pass through the
injector.The edge filters are not a substitute for
proper cleaning and covering of all fuel system
components during repair.
The bottom of each fuel injector is sealed to the
cylinder head with a1.5mmthick copper shim (gas-
ket) (Fig. 12). The correct thickness shim must
always be re-installed after removing an injector.
Fuel pressure in the injector circuit decreases after
injection. The injector needle valve is immediately
closed by the needle valve spring and fuel flow into
the combustion chamber is stopped. Exhaust gases
are prevented from entering the injector nozzle by
the needle valve.
DIAGNOSIS AND TESTINGÐFUEL INJECTOR
TEST
The fuel injectors are located in the top of the cyl-
inder head between the intake/exhaust valves (Fig.
14).A leaking fuel injector can cause fuel knock, poor
performance, black smoke, poor fuel economy and
rough engine idle. If fuel injector needle valve does
not operate properly, engine may misfire and produce
low power.
A leak in injection pump-to-injector high-pressure
fuel line can cause many of same symptoms as mal-
functioning injector. Inspect for leaks in high-pres-
sure lines before checking for malfunctioning fuel
injector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF UP TO APPROXIMATELY
120,000 kPa (17,400 psi) TO EACH INDIVIDUAL
INJECTOR THROUGH HIGH-PRESSURE LINES.
FUEL UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING. AVOID CONTACT WITH FUEL
SPRAY WHEN BLEEDING HIGH-PRESSURE FUEL
LINES.
WARNING: DO NOT BLEED AIR FROM FUEL SYS-
TEM OF A HOT ENGINE. DO NOT ALLOW FUEL TO
SPRAY ONTO EXHAUST MANIFOLD WHEN BLEED-
ING AIR FROM FUEL SYSTEM.
(1) To determine which fuel injector is malfunc-
tioning, run engine and isolate each cylinder using
DRB scan tool.The DRB scan tool lists the injec-
tor firing order in both cylinder numerical
order (1±2±3±4±5±6), and actual firing order
(1±5±3±6±2±4).
Fig. 14 Fuel Injector Connections
1 - CONNECTOR
2 - O-RING
3 - FERRULE
4 - FITTING
5 - FUEL LINE
6 - INJECTOR
Fig. 15 Inspecting Injector Operation
1 - HIGH-PRESSURE FUEL LINE
BR/BEFUEL INJECTION - DIESEL 14 - 99
FUEL INJECTOR (Continued)

FUEL TEMPERATURE SENSOR
DESCRIPTION
Two different fuel temperature sensors are used.
One of the sensors is located inside of the Bosch
VP44 fuel injection pump and is a non-serviceable
part. The other fuel temperature sensor is located in
the top of the fuel filter housing and is serviceable
(serviceable if replacing the fuel heater).
OPERATION
The sensor located in the Bosch VP44 fuel injection
pump is used to check fuel temperature within the
injection pump and to set a Diagnostic Trouble Code
(DTC) if a specific high fuel temperature has been
reached. If high temperature has been reached,
engine power will be de-rated by the Engine Control
Module (ECM).
The sensor located in the top of the fuel filter hous-
ing is used to control the fuel heater element. Refer
to Fuel Heater Description and Operation for addi-
tional information.
INTAKE AIR HEATER
DESCRIPTION
The intake manifold air heater element assembly
is located in the top of the intake manifold (Fig. 25).
OPERATION
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Man-
ifold Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater ele-
ments to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for an electrical operation and complete
description of the intake heaters, including pre-heat
and post-heat cycles.
REMOVAL
The 2 intake manifold air heater elements are
attached to a metal block located at the top of the
intake manifold (Fig. 26). If servicing either of the
heater elements, the entire block/element assembly
must be replaced.
(1) Disconnect both negative battery cables at both
batteries.
(2) Disconnect clamp from rubber hose at air
intake housing.
(3) Disconnect rubber hose at air intake housing.
Fig. 25 Air Heater Elements Location
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
Fig. 26 Intake Manifold Air Heater Element Location
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
14 - 104 FUEL INJECTION - DIESELBR/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

Test Six - Transmission In Overdrive Fourth Gear
This test checks line pressure at the overdrive
clutch in fourth gear range. Use 300 psi Test Gauge
C-3293-SP for this test. The test should be performed
on the road or on a chassis dyno.
(1) Remove tachometer; it is not needed for this
test.
(2) Move 300 psi Gauge to overdrive clutch pres-
sure test port. Then remove other gauge and reinstall
test port plug.
(3) Lower vehicle.
(4) Turn OD switch on.
(5) Secure test gauge so it can be viewed from
drivers seat.
(6) Start engine and shift into D range.
(7) Increase vehicle speed gradually until 3-4 shift
occurs and note gauge pressure.
(8) Pressure should be 469-496 kPa (68-72 psi)
with closed throttle and increase to 620-827 kPa (90-
120 psi) at 1/2 to 3/4 throttle. Note that pressure can
increase to around 896 kPa (130 psi) at full throttle.
(9) Return to shop or move vehicle off chassis
dyno.
PRESSURE TEST ANALYSIS CHART
TEST CONDITION INDICATION
Line pressure OK during
any one testPump and regulator
valve OK
Line pressure OK in R
but low in D, 2, 1Leakage in rear clutch
area (seal rings, clutch
seals)
Pressure low in D Fourth
Gear RangeOverdrive clutch piston
seal, or check ball
problem
Pressure OK in 1, 2 but
low in D3 and RLeakage in front clutch
area
Pressure OK in 2 but low
in R and 1Leakage in rear servo
Front servo pressure in 2 Leakage in servo; broken
servo ring or cracked
servo piston
Pressure low in all
positionsClogged filter, stuck
regulator valve, worn or
faulty pump, low oil level
Governor pressure too
high at idle speedGovernor pressure
solenoid valve system
fault. Refer to diagnostic
book.
Governor pressure low at
all mph figuresFaulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
TEST CONDITION INDICATION
Lubrication pressure low
at all throttle positionsClogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Line pressure high Output shaft plugged,
sticky regulator valve
Line pressure low Sticky regulator valve,
clogged filter, worn pump
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION
Air-pressure testing can be used to check transmis-
sion front/rear clutch and band operation. The test
can be conducted with the transmission either in the
vehicle or on the work bench, as a final check, after
overhaul.
Air-pressure testing requires that the oil pan and
valve body be removed from the transmission. The
servo and clutch apply passages are shown (Fig. 10).
Fig. 10 Air Pressure Test Passages
1 - LINE PRESSURE TO ACCUMULATOR
2 - REAR SERVO APPLY
3 - FRONT SERVO APPLY
4 - FRONT SERVO RELEASE
5 - PUMP SUCTION
6 - PUMP PRESSURE
7 - FRONT CLUTCH APPLY
8 - REAR CLUTCH APPLY
9 - TO TORQUE CONVERTOR
10 - TO COOLER
11 - FROM TORQUE CONVERTER
21 - 100 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)