Cooler DODGE RAM 2003 Service Repair Manual

(16) Disconnect gearshift cable from transmission
manual valve lever (Fig. 13).
(17) Disconnect the transmission vent hose from
the transmission.
(18) Support rear of engine with safety stand or
jack.
(19) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(20) Remove bolts securing rear support and cush-
ion to transmission and crossmember.
(21) Remove transfer case, if necessary.
(22) Disconnect transmission fluid cooler lines at
transmission fittings and clips.
(23) Remove all remaining converter housing bolts.
(24) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(25) Hold torque converter in place during trans-
mission removal.
(26) Lower transmission and remove (Fig. 14)
assembly from under the vehicle.
(27) To remove torque converter, carefully slide
torque converter out of the transmission.
DISASSEMBLY
(1) Drain fluid from transmission.
(2) Clean exterior of transmission with suitable
solvent or pressure washer.
(3) Remove the torque converter from the trans-
mission.(4) Remove the manual shift lever from the trans-
mission.
(5) Remove the input, output, and line pressure
sensors from the transmission case (Fig. 15).
Fig. 13 Gearshift Cable at Transmission - RFE
1 - GEARSHIFT CABLE
2 - RFE TRANSMISSION
3 - MANUAL LEVER
Fig. 14 Remove Transmission
1 - ENGINE
2 - TRANSMISSION
Fig. 15 Remove Input, Output, and Line Pressure
Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 497
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(6) Inspect the ends of the sensors for debris,
which may indicate the nature of the transmission
failure.
(7) Install Support Stand 8257 onto the transmis-
sion case (Fig. 16).
(8) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 17).
NOTE: When measuring the input shaft end-play,
two(stops(will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first(stop(felt when the input shaft is pulled out-
ward is the movement of the input shaft in the inputclutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(9) Remove the bolts holding the transmission
extension/adapter housing to the transmission case.
(10) Remove the extension/adapter housing from
the transmission case.
(11) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator
C-3339, measure and record the output shaft end-
play (Fig. 18).
(12) Remove the bolts holding the transmission oil
pan to the transmission case.
(13) Remove the transmission oil pan from the
transmission case.
(14) Remove the primary oil filter and the oil
cooler return filter (Fig. 19).
(15) Remove the cooler return filter bypass valve.
(16) Remove the bolts holding the valve body to
the transmission case (Fig. 20).
(17) Remove the valve body from the transmission
case.
(18) Remove the outer snap-ring securing the
transmission front cover into the transmission case
(Fig. 21).
(19) Remove the inner snap-ring securing the
transmission front cover to the oil pump (Fig. 21).
(20) Reaching through a case opening in the valve
body area with a long blunted tool, remove the trans-
mission front cover from the transmission case.
(21) Remove the bolts holding the oil pump into
the transmission case (Fig. 22).
Fig. 16 Install Support Stand - Tool 8257
1 - TOOL 8257
Fig. 17 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 18 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
21 - 498 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(22) Remove the oil pump. Hold inward on the
input shaft to prevent pulling the input clutch
assembly with the oil pump (Fig. 22).
NOTE: If the input shaft is not held during oil pump
removal, the input clutch assembly will attempt to
move forward with the oil pump and the numbers 2,
3, or 4 bearings inside the input clutch assembly
may become dislodged.
Fig. 19 Remove Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 20 Remove Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
Fig. 21 Remove Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 22 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 499
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

washers. Petroleum jelly can also be used to hold
parts in place during reassembly.
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the cooler filter bypass valve.
(3) Torque the bypass valve to specification. The
valve uses a tapered pipe thread and excessive
torque can damage the transmission case. Tighten
the cooler filter bypass valve to 4.5 N´m (40 in.lbs.).
(4) Install a new selector shaft seal using Seal
Installer 8253 (Fig. 32).
(5) Install the manual selector shaft and retaining
screw. Tighten the manual selector shaft retaining
screw to 28 N´m (250 in.lbs.).
(6) Install the park pawl, spring, and shaft (Fig.
33).
(7) Install the park rod and e-clip (Fig. 33).
(8) Install the park rod guide and snap-ring (Fig.
33).
Fig. 32 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
Fig. 33 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 503
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(49) Using Installer 8255, install the inner trans-
mission front cover snap-ring the remainder of the
way onto the oil pump (Fig. 49).
(50) Install the valve body (Fig. 50). Verify that
the pin on the manual lever has properly engaged
the TRS selector plate. Tighten the valve body to
transmission case bolts to 12 N´m (105 in.lbs.).
(51) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOTinstall the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(52)
Install the primary oil filter and the oil cooler
return filter (Fig. 51). Tighten the screw to hold the pri-
mary oil filter to the valve body to 4.5 N´m (40 in.lbs.).
Using Oil Filter Wrench 8321, tighten the cooler return
oil filter to the transmission case to 14 N´m (125 in.lbs.).
(53) Apply RTV silicone to the oil pan and install
the transmission oil pan. Tighten the bolts to 12 N´m
(105 in.lbs.).
(54)
Install the input, output, and line pressure sen-
sors (Fig. 52). Tighten the bolts to 12 N´m (105 in.lbs.).
Fig. 49 Seat Snap-Ring Using Tool 8255
1 - TOOL 8255
2 - SNAP-RING
Fig. 50 Install Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
Fig. 51 Install Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 52 Install Input, Output, and Line
Pressure Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 509
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(21) Connect wires to solenoid and pressure switch
assembly (Fig. 55) connector, input (Fig. 56) and out-
put (Fig. 57) speed sensors, and line pressure sensor
(Fig. 58). Be sure transmission harnesses are prop-
erly routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.(22) Install torque converter-to-driveplate bolts.
Tighten bolts to 31 N´m (270 in. lbs.).
(23) Install starter motor and cooler line bracket.
(24) Connect cooler lines to transmission.
(25) Install transmission fill tube.
(26) Install exhaust components, if necessary.
Fig. 55 Connect Transmission Solenoid
1 - TRANSMISSION
2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
Fig. 56 Connect Input Speed Sensor
1 - TRANSMISSION
2 - INPUT SPEED SENSOR
Fig. 57 Connect Output Speed Sensor
1 - TRANSMISSION
2 - OUTPUT SPEED SENSOR
Fig. 58 Connect Line Pressure Sensor
1 - TRANSMISSION
2 - LINE PRESSURE SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 511
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Output Shaft End Play 0.22-0.55
mm0.009-0.021
in.
Input Shaft End Play 0.46-0.89
mm0.018-0.035
in.
2C Clutch Pack
Clearance0.455-1.335
mm0.018-0.053
in.
4C Clutch Pack
Clearance0.770-1.390
mm0.030-0.055
in.
L/R Clutch Pack
Clearance1.00-1.74
mm0.039-0.069
in.
OD Clutch Pack
Clearance1.103-1.856
mm0.043-0.073
in.
Component Metric Inch
UD Clutch Pack
Clearance0.84-1.54
mm0.033-0.061
in.
Reverse Clutch Pack
Clearance0.81-1.24
mm0.032-0.049
in.
Recommended fluid MoparTAT F + 4
GEAR RATIOS
1ST 3.00:1
2ND 1.67:1
2ND Prime 1.50:1
3RD 1.0:1
4TH 0.75:1
5TH 0.67:1
REVERSE 3.00:1
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fitting, cooler line at trans 17.5 - 155
Bolt, torque convertor 31 23 -
Bolt/nut, crossmember 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Bolt, oil pan 11.8 - 105
Screw, primary fluid filter 4.5 - 40
Bolt, oil pump 28.2 - 250
Bolt, oil pump body to cover 4.5 - 40
Screw, plate to oil pump body 4.5 - 40
Bolt, valve body to case 11.8 - 105
Plug, pressure test port 5.1 - 45
Bolt, reaction shaft support 11.8 - 105
Screw, valve body to transfer plate 5.6 - 50
Screw, solenoid module to transfer plate 5.7 - 50
Screw, accumulator cover 4.5 - 40
Screw, detent spring 4.5 - 40
Bolt, input speed sensor 11.8 - 105
Bolt, output speed sensor 11.8 - 105
Bolt, line pressure sensor 11.8 - 105
Bolt, extension housing 54 40 -
Valve, cooler return filter bypass 4.5 - 40
Screw, manual valve cam retaining 4.5 - 40
Bolt, manual lever 28.2 - 250
21 - 534 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

BTSI FUNCTION CHECK
(1) Verify removal of ignition key allowed in PARK
position only.
(2) When the shift lever is in PARK, the ignition
key cylinder should rotate freely from off to lock.
When the shifter is in any other position, the ignition
key should not rotate from off to lock.
(3) Shifting out of PARK should be possible when
the ignition key cylinder is in the off position.
(4) Shifting out of PARK should not be possible
while applying normal force, and ignition key cylin-
der is in the run or start positions, unless the foot
brake pedal is depressed approximately 1/2 inch
(12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the accessory or
lock position.
(6) Shifting between any gear and NEUTRAL, or
PARK, may be done without depressing foot brake
with ignition switch in run or start positions.
(7) Engine starts must be possible with shifter
lever in PARK or NEUTRAL positions only. Engine
starts must not be possible in any position other than
PARK or NEUTRAL.
(8) With shifter lever in the:
²PARK position - Apply upward force on the shift
arm and remove pressure. Engine starts must be
possible.
²PARK position - Apply downward force on the
shift arm and remove pressure. Engine starts must
be possible.
²NEUTRAL position - Normal position. Engine
starts must be possible.²NEUTRAL position - Engine running and brakes
applied, apply upward force on the shift arm. Trans-
mission shall not be able to shift from neutral to
reverse.
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluid
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
(1) Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
(2) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(3) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
Fig. 65 Brake Transmission Interlock Mechanism
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 541
BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM (Continued)

²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The torque converter should be replaced whenever
a failure generates sludge and debris. This is neces-
sary because normal converter flushing procedures
will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transmission vent where it may be mis-
taken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level.
It is located on the right side of the engine. Be sure
to wipe all dirt from dipstick handle before removing.
The torque converter fills in both the P (PARK)
and N (NEUTRAL) positions. Place the selector lever
in P (PARK) to be sure that the fluid level check is
accurate.The engine should be running at idle
speed for at least one minute, with the vehicleon level ground.At normal operating temperature
(approximately 82 C. or 180 F.), the fluid level is cor-
rect if it is in the HOT region (cross-hatched area) on
the oil level indicator. The fluid level will be approx-
imately at the upper COLD hole of the dipstick at
70É F fluid temperature.
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
(1) Start engine and apply parking brake.
(2) Shift the transmission into DRIVE for approxi-
mately 2 seconds.
(3) Shift the transmission into REVERSE for
approximately 2 seconds.
(4) Shift the transmission into PARK.
(5) Hook up DRBtscan tool and select transmis-
sion.
(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the
chart. (Fig. 66)
(9) Adjust transmission fluid level shown on the
dipstick according to the chart.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmission for leaks.
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper service intervals (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION).
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Place a large diameter shallow drain pan
beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to
transmission.
(4) Loosen bolts holding rear of pan to transmis-
sion.
(5) Slowly separate front of pan away from trans-
mission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolts hold-
ing pan to transmission.
(7) While holding pan level, lower pan away from
transmission.
(8) Pour remaining fluid in pan into drain pan.
(9) Remove screw holding filter to valve body (Fig.
67).
21 - 542 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
FLUID AND FILTER (Continued)

(10) Separate filter from valve body and oil pump
and pour fluid in filter into drain pan.
(11) Remove and discard the oil filter seal from the
bottom of the oil pump.
(12) If replacing the cooler return filter, use Oil
Filter Wrench 8321 to remove the filter from the
transmission.
(13)
Dispose of used trans fluid and filter(s) properly.
INSPECTION
Inspect bottom of pan and magnet for excessive
amounts of metal. A light coating of clutch material
on the bottom of the pan does not indicate a problem
unless accompanied by a slipping condition or shift
lag. If fluid and pan are contaminated with excessive
amounts of debris, refer to the diagnosis section of
this group.
CLEANING
(1)Using a suitable solvent, clean pan and magnet.
(2) Using a suitable gasket scraper, clean original
sealing material from surface of transmission case
and the transmission pan.
INSTALLATION
(1) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
Fig. 66 Transmission Fluid Temperature Chart
Fig. 67 Transmission Filters - 4X4 Shown
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 543
FLUID AND FILTER (Continued)