automatic transmission DODGE RAM 2003 Service Repair Manual

EXTENSION HOUSING
BUSHING
REMOVAL
(1) Remove extension housing yoke seal.
(2) Insert Remover 6957 into the extension hous-
ing. Tighten tool to bushing and remove bushing
(Fig. 92).
INSTALLATION
(1) Align bushing oil hole with oil slot in extension
housing.
(2) Tap bushing into place with Installer 6951 and
Handle C-4171.
(3) Install new oil seal in housing using Seal
Installer C-3995-A (Fig. 93).
EXTENSION HOUSING SEAL
REMOVAL
(1) Raise vehicle.
(2) Mark propeller shaft and axle yoke for align-
ment reference.
(3) Disconnect and remove propeller shaft.
(4) Remove old seal with Seal Remover C-3985-B
(Fig. 94) from overdrive housing.
INSTALLATION
(1) Place seal in position on overdrive housing.
(2) Drive seal into overdrive housing with Seal
Installer C-3995-A (Fig. 95).
(3) Carefully guide propeller shaft slip yoke into
housing and onto output shaft splines. Align marks
made at removal and connect propeller shaft to rear
axle pinion yoke.
Fig. 92 Bushing Removal - Typical
1 - REMOVER
2 - EXTENSION HOUSING BUSHING
Fig. 93 Transmission Extension Housing Seal
Installation
1 - SPECIAL TOOL C-3995-A OR C-3972-A
2 - SPECIAL TOOL C-4471
Fig. 94 Removing Transmission Housing Yoke Seal
1 - SPECIAL TOOL C-3985-B
2 - SEAL
Fig. 95 Installing Transmission Housing Seal
1 - SPECIAL TOOL C-3995-A OR C-3972-A
2 - SPECIAL TOOL C-4471
21 - 200 AUTOMATIC TRANSMISSION - 46REDR

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 two primary causes.
(1) 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.
(2) 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
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 failuredue 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.
Fluid level is checked with the engine running at
curb idle speed, the transmission in NEUTRAL and
the transmission fluid at normal operating tempera-
ture.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.
The transmission fluid level can be checked two
ways.
PROCEDURE ONE
(1) Transmission fluid must be at normal operat-
ing temperature for accurate fluid level check. Drive
DRAUTOMATIC TRANSMISSION - 46RE 21 - 201

vehicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82ÉC (180ÉF).
(2) Position vehicle on level surface.
(3) Start and run engine at curb idle speed.
(4) Apply parking brakes.
(5) Shift transmission momentarily into all gear
ranges. Then shift transmission back to NEUTRAL.
(6) Clean top of filler tube and dipstick to keep
dirt from entering tube.
(7) Remove dipstick (Fig. 96) and check fluid level
as follows:
(a) Correct acceptable level is in crosshatch area.
(b) Correct maximum level is to MAX arrow
mark.
(c) Incorrect level is at or below MIN line.
(d) If fluid is low, add only enough MopartAT F
+4, Automatic Transmission fluid, to restore correct
level. Do not overfill.
PROCEDURE TWO
(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 engine.(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the
figure. (Fig. 97)
(9) Adjust transmission fluid level shown on the
dipstick according to the figure.
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.
Fig. 96 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
Fig. 97 46RE Fluid Fill Graph
21 - 202 AUTOMATIC TRANSMISSION - 46REDR
FLUID AND FILTER (Continued)

STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper service intervals (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION). The service fluid fill after a
filter change is approximately 3.8 liters (4.0 quarts).
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 (Fig. 98).
(4) Loosen bolts holding rear of pan to transmis-
sion.
(5) Slowly separate front of pan and gasket away
from transmission allowing the fluid to drain into
drain pan.
(6) Hold up pan and remove remaining bolt hold-
ing pan to transmission.
(7) While holding pan level, lower pan and gasket
away from transmission.
(8) Pour remaining fluid in pan into drain pan.
(9) Remove screws holding filter to valve body
(Fig. 99).
(10) Separate filter from valve body and pour fluid
in filter into drain pan.
(11) Dispose of used trans fluid and filter properly.
INSTALLATION
(1) Position a new transmission oil filter onto the
valve body.
(2) Install the screws to hold the filter to the valve
body. Tighten the screws to 4 N´m (35 in.lbs.).
(3) Clean the gasket surfaces of the transmission
oil pan and transmission pan rail.NOTE: The transmission pan oil gasket is reusable.
Inspect the sealing surfaces of the gasket. If the
sealing ribs on both surfaces appear to be in good
condition, clean the gasket of any foreign material
and reinstall.
(4) Position the oil pan gasket onto the oil pan.
(5) Position the oil pan and gasket onto the trans-
mission and install several bolts to hold the pan and
gasket to the transmission.
(6) Install the remainder of the oil pan bolts.
Tighten the bolts to 13.6 N´m (125 in.lbs.).
(7) Lower vehicle and fill transmission. (Refer to
21 - TRANSMISSION/AUTOMATIC/FLUID - STAN-
DARD PROCEDURE)
STANDARD PROCEDURE - TRANSMISSION
FILL
To avoid overfilling transmission after a fluid
change or overhaul, perform the following procedure:
(1) Remove dipstick and insert clean funnel in
transmission fill tube.
(2) Add following initial quantity of MopartAT F
+4, Automatic Transmission Fluid, to transmission:
(a) If only fluid and filter were changed, add3
pints (1-1/2 quarts)of ATF +4 to transmission.
(b) If transmission was completely overhauled,
or torque converter was replaced or drained, add
12 pints (6 quarts)of ATF +4 to transmission.
(3) Apply parking brakes.
(4) Start and run engine at normal curb idle
speed.
(5) Apply service brakes, shift transmission
through all gear ranges then back to NEUTRAL, set
parking brake, and leave engine running at curb idle
speed.
Fig. 98 Transmission Pan
1 - TRANSMISSION
2 - GASKET
3-PAN
Fig. 99 Transmission Filter
1 - TRANSMISSION
2 - FILTER
DRAUTOMATIC TRANSMISSION - 46RE 21 - 203
FLUID AND FILTER (Continued)

(6) Remove funnel, insert dipstick and check fluid
level. If level is low,add fluid to bring level to
MIN mark on dipstick.Check to see if the oil level
is equal on both sides of the dipstick. If one side is
noticably higher than the other, the dipstick has
picked up some oil from the dipstick tube. Allow the
oil to drain down the dipstick tube and re-check.
(7) Drive vehicle until transmission fluid is at nor-
mal operating temperature.
(8) With the engine running at curb idle speed, the
gear selector in NEUTRAL, and the parking brake
applied, check the transmission fluid level.
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fluid to bring level up to MAX arrow
mark.
When fluid level is correct, shut engine off, release
park brake, remove funnel, and install dipstick in fill
tube.
FRONT CLUTCH
DESCRIPTION
The front clutch assembly (Fig. 100) is composed of
the front clutch retainer, pressure plate, clutch
plates, driving discs, piston, piston return spring,return spring retainer, and snap-rings. The front
clutch is the forward-most component in the trans-
mission geartrain and is directly behind the oil pump
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 snap-ring is
used to cushion the application of the clutch pack.
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
Fig. 100 Front Clutch Components
1 - INNER PISTON SEAL 7 - CLUTCH DISCS
2 - CLUTCH PISTON 8 - RETAINER SNAP-RING
3 - CLUTCH PISTON SPRING RETAINER 9 - CLUTCH PISTON SPRINGS (9)
4 - CLUTCH PLATES 10 - OUTER PISTON SEAL
5 - CLUTCH PACK SNAP-RING (WAVED) 11 - FRONT CLUTCH RETAINER
6 - REACTION PLATE
21 - 204 AUTOMATIC TRANSMISSION - 46REDR
FLUID AND FILTER (Continued)

vent and one-way ball-check-valve located in the
clutch retainer. The check-valve is needed to elimi-
nate the possibility of plate drag caused by centrifu-
gal force acting on the residual fluid trapped in the
clutch piston retainer.
DISASSEMBLY
(1) Remove the waved snap-ring, reaction plate,
clutch plates, and clutch discs.
(2) Compress clutch piston retainer and piston
springs with Compressor Tool C-3863-A (Fig. 101).
(3) Remove retainer snap-ring and remove com-
pressor tool.
(4) Remove clutch piston springs (Fig. 102). Note
position of piston springs for assembly reference.
(5) Remove clutch piston from retainer with a
twisting motion.
(6) Remove and discard clutch piston inner and
outer seals.
Fig. 101 Removing Front Clutch Spring Retainer
Snap-Ring
1 - SPECIAL TOOL C-3863-A
2 - SNAP-RING
Fig. 102 Front Clutch Components
1 - INNER PISTON SEAL 7 - CLUTCH DISCS
2 - CLUTCH PISTON 8 - RETAINER SNAP-RING
3 - CLUTCH PISTON SPRING RETAINER 9 - CLUTCH PISTON SPRINGS (9)
4 - CLUTCH PLATES 10 - OUTER PISTON SEAL
5 - CLUTCH PACK SNAP-RING (WAVED) 11 - FRONT CLUTCH RETAINER
6 - REACTION PLATE
DRAUTOMATIC TRANSMISSION - 46RE 21 - 205
FRONT CLUTCH (Continued)

(7) Assemble Tool Handle C-4171 and Bushing
Remover SP-3629 (Fig. 103).
(8) Insert remover tool in bushing and drive bush-
ing straight out of clutch retainer.
INSPECTION
Inspect the front clutch components. Replace the
clutch discs if warped, worn, scored, burned or charred,
the lugs are damaged, or if the facing is flaking off.
Replace the steel plates and reaction plate if heavily
scored, warped, or broken. Be sure the driving lugs on
the discs and plate are also in good condition. The lugs
must not be bent, cracked or damaged in any way.
Replace the piston springs and spring retainer if
either are distorted, warped or broken.
Check the lug grooves in the clutch piston retainer.
The steel plates should slide freely in the slots. Replace
the piston retainer if the grooves are worn or damaged.
Also check action of the check ball in the piston
retainer. The ball must move freely and not stick.
Replace the retainer bushing if worn, scored, or
there is any doubt about bushing condition.
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 the clutch piston check ball. The ball should
be securely in place. Replace the piston if the ball is
missing, or seized in place.
ASSEMBLY
NOTE: The 46RE transmission uses three plates
and discs for the front clutch.
(1) Mount Bushing Installer SP-5511 on tool han-
dle (Fig. 104).
(2) Slide new bushing onto installer tool and start
bushing into retainer.
(3) Tap new bushing into place until installer tool
bottoms against clutch retainer.
(4) Remove installer tools and clean retainer thor-
oughly.
(5) Soak clutch discs in transmission fluid.
(6) Install new inner piston seal onto the outer
diameter of the clutch retainer inner hub.
(7) Install new outer seal onto the clutch piston.
Be sure seal lips of both seals face the interior of the
retainer.
(8) Lubricate new inner and outer piston seals
with Ru-GlydeŸ, or MopartDoor Ease.
(9) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.015 - 0.020 in. thick), can be
used to guide seals into place if necessary.
Fig. 103 Front Clutch Retainer Bushing
Replacement Tools
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3629
3 - SPECIAL TOOL SP-5511
4 - SPECIAL TOOL C-4171
5 - FRONT CLUTCH RETAINER
Fig. 104 Front Clutch Retainer Bushing
Replacement Tools
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3629
3 - SPECIAL TOOL SP-5511
4 - SPECIAL TOOL C-4171
5 - FRONT CLUTCH RETAINER
21 - 206 AUTOMATIC TRANSMISSION - 46REDR
FRONT CLUTCH (Continued)

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.
(10) Install and position nine clutch piston springs
(Fig. 105).
(11) Install spring retainer on top of piston
springs.
(12) Compress spring retainer and piston springs
with Tool C-3863-A.
(13) Install spring retainer snap-ring and remove
compressor tool.
(14) Install clutch plates and discs (Fig. 102).
Three clutch discs, three steel plates and one reac-
tion plate are required.
(15) Install reaction plate followed by waved snap-
ring.
(16) Check clutch pack clearance with feeler gauge
(Fig. 106). Clearance between waved spring and pres-
sure plate should 1.78 - 3.28 mm (0.070 - 0.129 in.).
If clearance is incorrect, clutch plates, clutch discs,
snap-ring, or pressure plate may have to be changed.
FRONT SERVO
DESCRIPTION
The kickdown servo (Fig. 107) consists of a two-
land piston with an inner piston, a piston rod and
guide, and a return spring. The dual-land piston uses
seal rings on its outer diameters and an O-ring for
the inner piston.
Fig. 105 Front Clutch Spring Position
1 - 9 SPRING CLUTCH
Fig. 106 Typical Method Of Measuring Front Clutch
Pack Clearance
1 - FEELER GAUGE
2 - WAVED SNAP-RING
3 - FEELER GAUGE
Fig. 107 Front Servo
1 - VENT
2 - INNER PISTON
3 - PISTON
4 - SPRING
5 - RELEASE PRESSURE
6 - APPLY PRESSURE
7 - PISTON ROD
DRAUTOMATIC TRANSMISSION - 46RE 21 - 207
FRONT CLUTCH (Continued)

OPERATION
The application of the piston is accomplished by
applying pressure between the two lands of the piston.
The pressure acts against the larger lower land to push
the piston downward, allowing the piston rod to extend
though its guide against the apply lever. Release of the
servo at the 2-3 upshift is accomplished by a combina-
tion of spring and line pressure, acting on the bottom of
the larger land of the piston. The small piston is used to
cushion the application of the band by bleeding oil
through a small orifice in the larger piston. The release
timing of the kickdown servo is very important to obtain
a smooth but firm shift. The release has to be very
quick, just as the front clutch application is taking
place. Otherwise, engine runaway or a shift hesitation
will occur. To accomplish this, the band retains its hold-
ing capacity until the front clutch is applied, giving a
small amount of overlap between them.
DISASSEMBLY
(1) Remove seal ring from rod guide (Fig. 108).
(2) Remove small snap-ring from servo piston rod.
Then remove piston rod, spring and washer from pis-
ton.
(3) Remove and discard servo component O-ring
and seal rings.
CLEANING
Clean the servo piston components (Fig. 109) with
solvent and dry them with compressed air.
INSPECTION
Inspect the servo components (Fig. 110). Replace
the springs if collapsed, distorted or broken. Replace
the guide, rod and piston if cracked, bent, or worn.
Discard the servo snap-ring if distorted or warped.
Fig. 108 Front Servo
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
5 - PISTON ROD GUIDE
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
Fig. 109 Front Servo
1 - VENT
2 - INNER PISTON
3 - PISTON
4 - SPRING
5 - RELEASE PRESSURE
6 - APPLY PRESSURE
7 - PISTON ROD
Fig. 110 Front Servo
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
5 - PISTON ROD GUIDE
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
21 - 208 AUTOMATIC TRANSMISSION - 46REDR
FRONT SERVO (Continued)

Check the servo piston bore for wear. If the bore is
severely scored, or damaged, it will be necessary to
replace the case.
Replace any servo component if doubt exists about
condition. Do not reuse suspect parts.
ASSEMBLY
Clean and inspect front servo components.
(1) Lubricate new o-ring and seal rings with petro-
leum jelly and install them on piston, guide and rod.
(2)
Install rod in piston. Install spring and washer on
rod. Compress spring and install snap-ring (Fig. 111).
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE
(1) Engine starts must be possible with shift lever
in PARK or NEUTRAL positions only. Engine starts
must not be possible in any other gear position.
(2) With the shift lever in the:
(a) PARK position - Apply upward force on the
shift arm and remove pressure. Engine starts must
be possible.
(b) PARK position - Apply downward force on
the shift arm and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.(d) NEUTRAL position - Engine running and
brakes applied, apply upward force on the shift
arm. Transmission shall not be able to shift from
neutral to reverse.
REMOVAL
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Disengage cable eyelet at transmission shift
lever and pull cable adjuster out of mounting bracket
(Fig. 112) or (Fig. 113).
Fig. 111 Front Servo
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
5 - PISTON ROD GUIDE
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
Fig. 112 Gearshift Cable at Transmission - RFE
1 - GEARSHIFT CABLE
2 - RFE TRANSMISSION
3 - MANUAL LEVER
Fig. 113 Gearshift Cable at Transmission - RE
1 - GEARSHIFT CABLE
2 - RE TRANSMISSION
3 - MANUAL LEVER
DRAUTOMATIC TRANSMISSION - 46RE 21 - 209
FRONT SERVO (Continued)