clutch DODGE RAM 2003 Service Repair Manual

(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. 85).
(4) Rotate transmission into a horizontal position
and remove the input shaft retainer.
(5) Install shims necessary to achieve an end-play
of 0-0.10 mm (0-0.004 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.
(7) Install input shaft oil guide with C-3972-A and
Handle C-4171.
(8) Apply sealer to the input shaft retainer and
install retainer onto the clutch housing. Install bolts
and tighten to 28 N´m (20 ft.lbs.).
REVERSE GEAR
(1) Install reverse shift fork and synchronizer as
an assembly onto the reverse shift rail and output
shaft (Fig. 86).
NOTE: Raised square shoulder and snap-ring on
the synchro face the case.(2) Install roll-pin securing the reverse shift fork
to the reverse shift rail with 6 mm (7/32 in.) punch
and a hammer.
(3) Install reverse gear bearing sleeve onto the
output shaft with Installer 6446 if necessary (Fig.
87).
Fig. 85 MEASURE COUNTERSHAFT END-PLAY
1 - EXTENSION ROD
2 - DIAL INDICATOR
3 - COUNTERSHAFT
Fig. 86 REVERSE SHIFT FORK AND SYNCHRO
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 87 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
DRMANUAL TRANSMISSION - NV5600 21 - 117
MANUAL TRANSMISSION - NV5600 (Continued)

(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. 94).
(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. 95).
(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.).
(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.
96). Check lubricant level in transfer case if
equipped.
Fig. 94 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
Fig. 95 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
21 - 120 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

SPECIFICATIONS - NV5600
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Crossover Cam and Detent 48 35 -
Bolt, Input Retainer 28 20 -
Bolt, 5-6 Crossover Bracket 28 20 -
Bolt, Clutch Housing 48 35 -
Bolt, Extension/Adapter Housing 48 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 Lever 22 16 -
Plug, Fill 30 22 -
Nut, Output Shaft 339 250 -
SPECIAL TOOLS
REMOVER 8155
INSTALLER 8156
HANDLE C-4171
INSTALLER C-3972-A
INSTALLER 8154
21 - 122 MANUAL TRANSMISSION - NV5600DR
MANUAL TRANSMISSION - NV5600 (Continued)

AUTOMATIC TRANSMISSION - 46RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 46RE
DESCRIPTION........................131
OPERATION..........................133
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................139
DIAGNOSIS AND TESTING - PRELIMINARY. . 139
DIAGNOSIS AND TESTING - ROAD
TESTING...........................139
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................140
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION........................143
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................143
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS...........................144
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................156
REMOVAL............................156
DISASSEMBLY........................158
CLEANING...........................164
INSPECTION.........................165
ASSEMBLY...........................165
INSTALLATION........................173
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............175
SPECIFICATIONS
TRANSMISSION.....................187
SPECIAL TOOLS
RE TRANSMISSION..................189
ACCUMULATOR
DESCRIPTION........................191
OPERATION..........................192
INSPECTION.........................192
BANDS
DESCRIPTION........................193
OPERATION..........................193
ADJUSTMENTS
ADJUSTMENT - BANDS...............193
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION........................194
OPERATION..........................194
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......195
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................195ELECTRONIC GOVERNOR
DESCRIPTION........................196
OPERATION..........................196
REMOVAL............................198
INSTALLATION........................199
EXTENSION HOUSING BUSHING
REMOVAL............................200
INSTALLATION........................200
EXTENSION HOUSING SEAL
REMOVAL............................200
INSTALLATION........................200
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............201
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................201
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................201
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................201
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............203
STANDARD PROCEDURE - TRANSMISSION
FILL...............................203
FRONT CLUTCH
DESCRIPTION........................204
OPERATION..........................204
DISASSEMBLY........................205
INSPECTION.........................206
ASSEMBLY...........................206
FRONT SERVO
DESCRIPTION........................207
OPERATION..........................208
DISASSEMBLY........................208
CLEANING...........................208
INSPECTION.........................208
ASSEMBLY...........................209
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................209
REMOVAL............................209
INSTALLATION........................210
ADJUSTMENTS
GEARSHIFT CABLE...................211
OIL PUMP
DESCRIPTION........................212
OPERATION..........................212
DISASSEMBLY........................212
DRAUTOMATIC TRANSMISSION - 46RE 21 - 129

CLEANING...........................214
INSPECTION.........................214
ASSEMBLY...........................215
OUTPUT SHAFT FRONT BEARING
REMOVAL............................217
INSTALLATION........................217
OUTPUT SHAFT REAR BEARING
REMOVAL............................217
INSTALLATION........................217
OVERDRIVE CLUTCH
DESCRIPTION........................218
OPERATION..........................218
OVERDRIVE SWITCH
DESCRIPTION........................218
OPERATION..........................218
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS..............219
REMOVAL............................219
INSTALLATION........................219
OVERDRIVE UNIT
REMOVAL............................220
DISASSEMBLY........................220
CLEANING...........................227
INSPECTION.........................227
ASSEMBLY...........................228
INSTALLATION........................236
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION........................237
OPERATION..........................237
DISASSEMBLY........................238
CLEANING...........................238
INSPECTION.........................238
ASSEMBLY...........................239
PISTONS
DESCRIPTION........................241
OPERATION..........................241
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION........................242
OPERATION..........................243
DISASSEMBLY........................243
INSPECTION.........................245
ASSEMBLY...........................245
REAR CLUTCH
DESCRIPTION........................248
OPERATION..........................249
DISASSEMBLY........................249
CLEANING...........................250
INSPECTION.........................250
ASSEMBLY...........................250REAR SERVO
DESCRIPTION........................252
OPERATION..........................252
DISASSEMBLY........................252
CLEANING...........................252
ASSEMBLY...........................253
SHIFT MECHANISM
DESCRIPTION........................253
OPERATION..........................253
SOLENOID
DESCRIPTION........................253
OPERATION..........................254
SPEED SENSOR
DESCRIPTION........................254
OPERATION..........................254
THROTTLE VALVE CABLE
DESCRIPTION........................254
ADJUSTMENTS - THROTTLE VALVE
CABLE.............................255
TORQUE CONVERTER
DESCRIPTION........................257
OPERATION..........................261
REMOVAL............................262
INSTALLATION........................262
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION........................262
OPERATION..........................262
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE........262
TRANSMISSION RANGE SENSOR
DESCRIPTION........................263
OPERATION..........................263
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS)................264
REMOVAL............................265
INSTALLATION........................266
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION........................267
OPERATION..........................267
VALVE BODY
DESCRIPTION........................267
OPERATION..........................272
REMOVAL............................286
DISASSEMBLY........................287
CLEANING...........................298
INSPECTION.........................298
ASSEMBLY...........................299
INSTALLATION........................307
ADJUSTMENTS - VALVE BODY...........308
21 - 130 AUTOMATIC TRANSMISSION - 46REDR

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 thelow/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.
DRAUTOMATIC TRANSMISSION - 46RE 21 - 131

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 can also be engaged in
the manual second gear position if high transmission
temperatures are sensed by the PCM. The torque
converter clutch will disengage momentarily 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 economy 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
DRAUTOMATIC TRANSMISSION - 46RE 21 - 133
AUTOMATIC TRANSMISSION - 46RE (Continued)

PARK POWERFLOW
As the engine is running and the crankshaft is
rotating, the flexplate and torque converter, which
are also bolted to it, are all rotating in a clockwise
direction as viewed from the front of the engine. The
notched hub of the torque converter is connected to
the oil pump's internal gear, supplying the transmis-
sion with oil pressure. As the converter turns, it
turns the input shaft in a clockwise direction. As the
input shaft is rotating, the front clutch hub-rear
clutch retainer and all their associated parts are also
rotating, all being directly connected to the input
shaft. The power flow from the engine through the
front clutch hub and rear clutch retainer stops at the
rear clutch retainer. Therefore, no power flow to the
output shaft occurs because no clutches are applied.
The only mechanism in use at this time is the park-
ing sprag (Fig. 3), which locks the parking gear on
the output shaft to the transmission case.
NEUTRAL POWERFLOW
With the gear selector in the NEUTRAL position
(Fig. 4), the power flow of the transmission is essen-
tially the same as in the park position. The only
operational difference is that the parking sprag has
been disengaged, unlocking the output shaft from the
transmission case and allowing it to move freely.
Fig. 3 Park Powerflow
1 - PAWL ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5-PAWL
21 - 134 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

REVERSE POWERFLOW
When the gear selector is moved into the
REVERSE position (Fig. 5), the front clutch and the
rear band are applied. With the application of the
front clutch, engine torque is applied to the sun gear,
turning it in a clockwise direction. The clockwise
rotation of the sun gear causes the rear planet pin-
ions to rotate against engine rotation in a counter-
clockwise direction. The rear band is holding the low
reverse drum, which is splined to the rear carrier.Since the rear carrier is being held, the torque from
the planet pinions is transferred to the rear annulus
gear, which is splined to the output shaft. The output
shaft in turn rotates with the annulus gear in a
counterclockwise direction giving a reverse gear out-
put. The entire transmission of torque is applied to
the rear planetary gearset only. Although there is
torque input to the front gearset through the sun
gear, no other member of the gearset is being held.
During the entire reverse stage of operation, the
front planetary gears are in an idling condition.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
DRAUTOMATIC TRANSMISSION - 46RE 21 - 135
AUTOMATIC TRANSMISSION - 46RE (Continued)

FIRST GEAR POWERFLOW
When the gearshift lever is moved into the DRIVE
position the transmission goes into first gear (Fig. 6).
As soon as the transmission is shifted from PARK or
NEUTRAL to DRIVE, the rear clutch applies, apply-
ing the rear clutch pack to the front annulus gear.
Engine torque is now applied to the front annulus
gear turning it in a clockwise direction. With the
front annulus gear turning in a clockwise direction, it
causes the front planets to turn in a clockwise direc-
tion. The rotation of the front planets cause the sun
to revolve in a counterclockwise direction. The sun
gear now transfers its counterclockwise rotation to
the rear planets which rotate back in a clockwisedirection. With the rear annulus gear stationary, the
rear planet rotation on the annulus gear causes the
rear planet carrier to revolve in a counterclockwise
direction. The rear planet carrier is splined into the
low-reverse drum, and the low reverse drum is
splined to the inner race of the over-running clutch.
With the over-running clutch locked, the planet car-
rier is held, and the resulting torque provided by the
planet pinions is transferred to the rear annulus
gear. The rear annulus gear is splined to the output
shaft and rotated along with it (clockwise) in an
underdrive gear reduction mode.
Fig. 6 First Gear Powerflow
1 - OUTPUT SHAFT 5 - OVER-RUNNING CLUTCH HOLDING
2 - OVER-RUNNING CLUTCH HOLDING 6 - INPUT SHAFT
3 - REAR CLUTCH APPLIED 7 - REAR CLUTCH APPLIED
4 - OUTPUT SHAFT 8 - INPUT SHAFT
21 - 136 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)