wiring DODGE RAM 2003 Service Repair Manual

ment Tool 6227-2. Overdrive unit cannot be installed
if splines are not aligned. If splines have rotated out
of alignment, unit will have to be disassembled to
realign splines.
(9)
Carefully slide Alignment Tool 6227-2 out of over-
drive planetary gear and overrunning clutch splines.
(10) Raise overdrive unit and carefully slide it
straight onto intermediate shaft. Insert park rod into
park lock reaction plug at same time. Avoid tilting
overdrive during installation as this could cause
planetary gear and overrunning clutch splines to
rotate out of alignment. If this occurs, it will be nec-
essary to remove and disassemble overdrive unit to
realign splines.
(11) Work overdrive unit forward on intermediate
shaft until seated against transmission case.
(12) Install bolts attaching overdrive unit to trans-
mission unit. Tighten bolts in diagonal pattern to 34
N´m (25 ft-lbs).
(13) Connect the transmission speed sensor and
overdrive wiring connectors.
(14) Install the transfer case, if equipped.
(15) Align and install rear propeller shaft, if nec-
essary. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION)
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunning clutch (Fig. 184) consists of an
inner race, an outer race (or cam), rollers and
springs, and the spring retainer. The number of roll-
ers and springs depends on what transmission and
which overrunning clutch is being dealt with.
OPERATION
As the inner race is rotated in a clockwise direction
(as viewed from the front of the transmission), the
race causes the rollers to roll toward the springs,
causing them to compress against their retainer. The
compression of the springs increases the clearance
between the rollers and cam. This increased clear-
ance between the rollers and cam results in a free-
wheeling condition. When the inner race attempts to
rotate counterclockwise, the action causes the rollers
to roll in the same direction as the race, aided by the
pushing of the springs. As the rollers try to move in
the same direction as the inner race, they are
wedged between the inner and outer races due to the
design of the cam. In this condition, the clutch is
locked and acts as one unit.
DISASSEMBLY
(1) Remove the overdrive piston (Fig. 185).
(2) Remove the overdrive piston retainer bolts.
(3) Remove overdrive piston retainer.
(4) Remove case gasket.
Fig. 185 Overdrive Piston Removal
1 - OVERDRIVE CLUTCH PISTON
2 - INTERMEDIATE SHAFT
3 - SELECTIVE SPACER
4 - PISTON RETAINER
Fig. 184 Overrunning Clutch
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
DRAUTOMATIC TRANSMISSION - 48RE 21 - 415
OVERDRIVE UNIT (Continued)

Mechanical State Electronic Display
(Ignition Unlocked)Electronic Display
(Ignition On)
Indicated Gear Position Transmission
StatusColumn Shifter
Position
P P P Vehicle is in PARK
with the pawl
engaged.In the PARK gate.
R The PARK pawl is
disengaged and the
vehicle is free to
roll, but REVERSE
is not engaged.Between the PARK
and REVERSE
gates.
R R R The transmission is
hydraulically in
REVERSE.In the REVERSE
gate.
N The transmission is
transitioning
between REVERSE
and NEUTRAL.Between the
REVERSE and
NEUTRAL gates.
N N N The vehicle is in
NEUTRAL.In the NEUTRAL
gate.
N The transmission is
transitioning
between NEUTRAL
and DRIVE, but is
not in DRIVE.Between the
NEUTRAL and
DRIVE gates.
D D D The transmission is
hydraulically in
DRIVE.In the DRIVE gate,
2 2 2 The transmission is
hydraulically in
Manual SECOND.In the SECOND
gate.
1 1 1 The transmission is
hydraulically in
Manual FIRST.In the FIRST gate.
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS)
NOTE: For all circuit identification in the following
steps, Refer to the appropriate Wiring Information.
(1) Raise vehicle on suitable hoist.
(2) Disconnect the vehicle's shift cable from the
manual lever.
(3) With the manual lever in the PARK position
(the PARK position is with the manual lever moved
to the full rearward position), measure the resistance
between the Park/Neutral Position Sense pin of the
TRS and the transmission case. The resistance
should be less than 5 ohms.(4) With the manual lever in the NEUTRAL posi-
tion (the NEUTRAL position is with the manual
lever moved two detents forward of the full rearward
position), measure the resistance between the Park/
Neutral Position Sense pin of the TRS and the trans-
mission case. The resistance should be less than 5
ohms.
(5) If the resistance is greater than 5 ohms in
either of the previous steps, check for a dirty contact
between the tip of the TRS rod and the valve body
manual lever. If the contact is OK, replace the TRS.
(6) With the manual lever in the REVERSE posi-
tion (the REVERSE position is with the manual lever
moved one detent forward of the full rearward posi-
tion), measure the resistance between the Fused
Ignition Switch Output and the Back-up Lamp feed
pins of the TRS. The resistance should be less than 5
21 - 442 AUTOMATIC TRANSMISSION - 48REDR
TRANSMISSION RANGE SENSOR (Continued)

ohms. If the resistance is greater than 5 ohms,
replace the TRS.
(7) With the manual lever in the PARK position
(the PARK position is with the manual lever moved
to the full rearward position), measure the resistance
between the Transmission Range Sensor MUX and
the Transmission Range Sensor 5V Supply pins of
the TRS. The resistance should be 522.2 ohms. If the
resistance is not correct, replace the TRS.
(8) With the manual lever in the REVERSE posi-
tion (the REVERSE position is with the manual lever
moved one detent forward of the full rearward posi-
tion), measure the resistance between the Transmis-
sion Range Sensor MUX and the Transmission Range
Sensor 5V Supply pins of the TRS. The resistance
should be 206.2 ohms. If the resistance is not correct,
replace the TRS.
(9) With the manual lever in the NEUTRAL posi-
tion (the NEUTRAL position is with the manual
lever moved two detents forward of the full rearward
position), measure the resistance between the Trans-
mission Range Sensor MUX and the Transmission
Range Sensor 5V Supply pins of the TRS. The resis-
tance should be 108.6 ohms. If the resistance is not
correct, replace the TRS.
(10) With the manual lever in the DRIVE position
(the DRIVE position is with the manual lever moved
three detents forward of the full rearward position),
measure the resistance between the Transmission
Range Sensor MUX and the Transmission Range
Sensor 5V Supply pins of the TRS. The resistance
should be 59.9 ohms. If the resistance is not correct,
replace the TRS.
(11) With the manual lever in the SECOND posi-
tion (the SECOND position is with the manual lever
moved one detent rearward of the full forward posi-
tion), measure the resistance between the Transmis-
sion Range Sensor MUX and the Back-up Lamp feed
pins of the TRS. The resistance should be 31.9 ohms.
If the resistance is not correct, replace the TRS.
(12) With the manual lever in the LOW position
(the LOW position is with the manual lever moved to
the full forward position), measure the resistance
between the Transmission Range Sensor MUX and
the Back-up Lamp feed pins of the TRS. The resis-
tance should be 13.7 ohms. If the resistance is not
correct, replace the TRS.REMOVAL
(1) Raise vehicle and position drain pan under the
transmission range sensor (TRS).
(2) Move the transmission manual lever to the
manual LOW position. The manual LOW position is
with the manual lever in the forward-most detent.
(3) Disengage the wiring connector from the TRS.
(4) Remove the two screws holding the TRS to the
TRS mounting bracket.
(5) Remove the TRS (Fig. 244) from the TRS
mounting bracket by pulling it straight out of the
bracket.
(6) Loosen the TRS mounting bracket in the trans-
mission case using Adapter 8581 (Fig. 245).
Fig. 244 Remove Transmission Range Sensor
1 - SOLENOID CASE CONNECTOR
2 - TRS MOUNTING BRACKET
3 - TRANSMISSION RANGE SENSOR
Fig. 245 Loosen the TRS Mounting Bracket
1 - SOLENOID CASE CONNECTOR
2 - TRS MOUNTING BRACKET
3 - ADAPTER 8581
DRAUTOMATIC TRANSMISSION - 48RE 21 - 443
TRANSMISSION RANGE SENSOR (Continued)

(7) Remove the TRS mounting bracket (Fig. 246)
from the transmission case.
INSTALLATION
(1) Move the transmission manual shaft lever to
the manual LOW position.
(2) Install the TRS mounting bracket into the
transmission case. Using Adapter 8581 (Fig. 247),
tighten the mounting bracket to 34 N´m (300 in.lbs.).
(3) Install the TRS (Fig. 248) into the mounting
bracket with the wiring connector facing the front of
the transmission.
(4) Install the two screws to hold the TRS to the
mounting bracket. Tighten the screws to 3.4 N´m (30
in.lbs.).
(5) Verify proper sensor operation (Fig. 249).(6) Move the transmission manual shaft lever to
the PARK position.
(7) Connect TRS wiring connector to the TRS and
lower vehicle.
(8) Refill the transmission fluid to the correct
level.
Fig. 246 Remove TRS Mounting Bracket
1 - SOLENOID CASE CONNECTOR
2 - TRS MOUNTING BRACKET
Fig. 247 Tighten the TRS Mounting Bracket
1 - SOLENOID CASE CONNECTOR
2 - TRS MOUNTING BRACKET
3 - ADAPTER 8581
Fig. 248 Remove Transmission Range Sensor
1 - SOLENOID CASE CONNECTOR
2 - TRS MOUNTING BRACKET
3 - TRANSMISSION RANGE SENSOR
Fig. 249 Transmission Range Sensor Operation
1 - NEUTRAL CONTACT
2 - MANUAL LEVER AND SENSOR PLUNGER IN REVERSE
POSITION
3 - PARK CONTACT
4 - TRANSMISSION RANGE SENSOR
21 - 444 AUTOMATIC TRANSMISSION - 48REDR
TRANSMISSION RANGE SENSOR (Continued)

(4) Lower the vehicle.
(5) Remove the dash panel insulation pad as nec-
essary to access the gearshift cable grommet (Fig.
70).
(6) Remove grommet from the dash panel.
(7) Remove any steering column trim necessary to
access the gearshift cable and BTSI mechanism.
(8) Disconnect the BTSI wiring connector.
(9) Disconnect cable at lower column bracket and
shift lever pin and pull the cable through the dash
panel opening into the vehicle (Fig. 71).
(10) Remove gearshift cable from vehicle.INSTALLATION
(1) Route the transmission end of the gearshift
cable through the opening in the dash panel (Fig.
72).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column
bracket so the retaining ears (Fig. 73) are engaged
and snap the cable eyelet onto the shift lever ball
stud.
Fig. 70 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 71 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
Fig. 72 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 73 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 545
GEARSHIFT CABLE (Continued)

REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.
(3) Remove the wiring connector from the input
speed sensor (Fig. 91).
(4) Remove the bolt holding the input speed sensor
to the transmission case.
(5) Remove the input speed sensor from the trans-
mission case.
INSTALLATION
(1) Install the input speed sensor into the trans-
mission case.
(2) Install the bolt to hold the input speed sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the input
speed sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
LINE PRESSURE (LP) SENSOR
DESCRIPTION
The TCM utilizes a closed-loop system to control
transmission line pressure. The system contains a
variable force style solenoid, the Pressure Control
Solenoid, mounted on the side of the solenoid and
pressure switch assembly. The solenoid is duty cycle
controlled by the TCM to vent the unnecessary line
pressure supplied by the oil pump back to the sump.The system also contains a variable pressure style
sensor, the Line Pressure Sensor, which is a direct
input to the TCM. The line pressure solenoid moni-
tors the transmission line pressure and completes the
feedback loop to the TCM. The TCM uses this infor-
mation to adjust its control of the pressure control
solenoid to achieve the desired line pressure.
OPERATION
The TCM calculates the desired line pressure
based upon inputs from the transmission and engine.
The TCM calculates the torque input to the trans-
mission and uses that information as the primary
input to the calculation. The line pressure is set to a
predetermined value during shifts and when the
transmission is in the PARK and NEUTRAL posi-
tions. This is done to ensure consistent shift quality.
During all other operation, the actual line pressure is
compared to the desired line pressure and adjust-
ments are made to the pressure control solenoid duty
cycle.
REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.
(3) Remove the wiring connector from the line
pressure sensor (Fig. 92).
(4) Remove the bolt holding the line pressure sen-
sor to the transmission case.
(5) Remove the line pressure sensor from the
transmission case.
Fig. 91 Input Speed Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
Fig. 92 Line Pressure Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 559
INPUT SPEED SENSOR (Continued)

INSTALLATION
(1) Install the line pressure sensor into the trans-
mission case.
(2) Install the bolt to hold the line pressure sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the line pres-
sure sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
LOW/REVERSE CLUTCH
DISASSEMBLY
(1) Remove the inner overrunning clutch snap-ring
from the low/reverse clutch retainer (Fig. 93).
(2) Remove the outer low/reverse reaction plate
flat snap-ring (Fig. 93).
(3) Remove the low/reverse clutch and the over-
running clutch from the low/reverse clutch retainer
as an assembly (Fig. 93).
(4) Separate the low/reverse clutch from the over-
running clutch.
Fig. 93 Low/Reverse Clutch Assembly
1 - SNAP-RING (SELECT) 8 - SEAL
2 - REACTION PLATE 9 - BELLEVILLE SPRING
3 - DISC 10 - RETAINER
4 - PLATE 11 - SNAP-RING
5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH
6 - SEAL 13 - SNAP-RING
7 - PISTON
21 - 560 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
LINE PRESSURE (LP) SENSOR (Continued)

into the appropriate oil pump valve body bore (Fig.
102) (Fig. 103).
(4) Place the separator plate onto the oil pump
body (Fig. 101).
(5) Install the screws to hold the separator plate
onto the oil pump body (Fig. 101). Tighten the screws
to 4.5 N´m (40 in.lbs.).
(6) Position the oil pump cover onto the locating
dowels (Fig. 100).
(7) Seat the two oil pump halves together and
install all bolts finger tight.
(8) Torque all bolts down slowly starting in the
center and working outward. The correct torque is
4.5 N´m (40 in.lbs.).
(9) Verify that the oil pump gears rotate freely and
smoothly.
(10) Position the reaction shaft support into the oil
pump (Fig. 100).
(11) Install and torque the bolts to hold the reac-
tion shaft support to the oil pump (Fig. 100). The cor-
rect torque is 12 N´m (105 in.lbs.).
OIL PUMP FRONT SEAL
REMOVAL
(1) Remove transmission from the vehicle.
(2) Remove the torque converter from the trans-
mission.
(3) Using a screw mounted in a slide hammer,
remove the oil pump front seal.
INSTALLATION
(1) Clean seal bore of the oil pump of any residue
or particles from the original seal.
(2) Install new oil seal in the oil pump housing
using Seal Installer C-3860-A (Fig. 104).
OUTPUT SPEED SENSOR
DESCRIPTION
The Input and Output Speed Sensors are two-wire
magnetic pickup devices that generate AC signals as
rotation occurs. They are mounted in the left side of
the transmission case and are considered primary
inputs to the Transmission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on
how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC
voltage is generated and sent to the TCM. The TCM
interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal
in a similar fashion, though its coil is excited by rota-tion of the rear planetary carrier lugs. The TCM
interprets this information as output shaft rpm.
The TCM compares the input and output speed
signals to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
The TCM also compares the input speed signal and
the engine speed signal to determine the following:
²Torque converter clutch slippage
²Torque converter element speed ratio
REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.
(3) Remove the wiring connector from the output
speed sensor (Fig. 105).
(4) Remove the bolt holding the output speed sen-
sor to the transmission case.
(5) Remove the output speed sensor from the
transmission case.
INSTALLATION
(1) Install the output speed sensor into the trans-
mission case.
(2) Install the bolt to hold the output speed sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the output
speed sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
Fig. 104 Install Oil Pump Front Seal
1 - TOOL C-3860-A
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 567
OIL PUMP (Continued)

INSTALLATION
NOTE: There is enough slack in the wire to pull out
the connector from the lever.
(1) Pull the connector out of the lever just enough
to grasp it.
CAUTION: Be careful not to bend the pins on the
overdrive off switch. Use care when installing the
switch, as it is not indexed, and can be accidentally
installed incorrectly.
(2) Install the overdrive off switch into the connec-
tor (Fig. 109)
(3) Push the overdrive off switch and wiring into
the shift lever.
(4) Install the overdrive off switch retainer onto
the shift lever.
PISTONS
DESCRIPTION
There are several sizes and types of pistons used in
an automatic transmission. Some pistons are used to
apply clutches, while others are used to apply bands.
They all have in common the fact that they are round or
circular in shape, located within a smooth walled cylin-
der, which is closed at one end and converts fluid pres-
sure into mechanical movement. The fluid pressure
exerted on the piston is contained within the system
through the use of piston rings or seals.
OPERATION
The principal which makes this operation possible
is known as Pascal's Law. Pascal's Law can be statedas: ªPressure on a confined fluid is transmitted
equally in all directions and acts with equal force on
equal areas.º
PRESSURE
Pressure (Fig. 110) is nothing more than force (lbs.)
divided by area (in or ft.), or force per unit area.
Given a 100 lb. block and an area of 100 sq. in. on
the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.
PRESSURE ON A CONFINED FLUID
Pressure is exerted on a confined fluid (Fig. 111) by
applying a force to some given area in contact with
the fluid. A good example of this is a cylinder filled
with fluid and equipped with a piston that is closely
fitted to the cylinder wall. If a force is applied to the
piston, pressure will be developed in the fluid. Of
course, no pressure will be created if the fluid is not
confined. It will simply ªleakº past the piston. There
must be a resistance to flow in order to create pres-
sure. Piston sealing is extremely important in
hydraulic operation. Several kinds of seals are used
to accomplish this within a transmission. These
include but are not limited to O-rings, D-rings, lip
seals, sealing rings, or extremely close tolerances
between the piston and the cylinder wall. The force
exerted is downward (gravity), however, the principle
remains the same no matter which direction is taken.
The pressure created in the fluid is equal to the force
applied, divided by the piston area. If the force is 100
lbs., and the piston area is 10 sq. in., then the pres-
sure created equals 10 PSI. Another interpretation of
Fig. 109 Install the Overdrive Off Switch
1 - GEAR SHIFT LEVER
2 - OVERDRIVE OFF SWITCH WIRING CONNECTOR
3 - OVERDRIVE OFF SWITCH
Fig. 110 Force and Pressure Relationship
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 569
OVERDRIVE SWITCH (Continued)

²A flashing operating mode LED for the desired
gear indicates that a shift to that position has been
requested, but all of the driver controllable conditions
have not been met. This is in an attempt to notify
the driver that the transmission needs to be put into
NEUTRAL, the vehicle speed is too great, or some
other condition outlined (other than a diagnostic fail-
ure that would prevent this shift) elsewhere (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/TRANSFER CASE CONTROL MODULE -
OPERATION) is not met. Note that this flashing will
continue indefinitely until the conditions are eventu-
ally met, or the selector switch position is changed,
or if diagnostic routines no longer allow the
requested shift.
²If the driver attempts to make a shift into trans-
fer case NEUTRAL, and any of the driver controlla-
ble conditions are not met, the request will be
ignored until all of the conditions are met or until
the NEUTRAL select button is released. Additionally
the neutral lamp will flash, or begin to flash while
the button is depressed and operator controllable
conditions are not being met. All of the LED's except
the Neutral will flash if any of the operator control-
lable conditions for shifting are not met while the
Neutral button is depressed. This9toggle9type of fea-
ture is necessary because the TCCM would interpret
another request immediately after the shift into
transfer case NEUTRAL has completed.
²No LED's illuminated indicate a fault in the
transfer case control system.
SHIFT MOTOR
DESCRIPTION
The shift motor (Fig. 85) consists of a permanent
magnet D.C. motor with gear reduction to convert a
high speed-low torque device into a low speed-high
torque device. The output of the device is coupled to
a shaft which internally moves the mode and range
forks that change the transfer case operating ranges.
The motor is rated at 25 amps maximum at 72É F
with 10 volts at the motor leads.
OPERATION
The transfer case shift motor responds to the
Transfer Case Control Module (TCCM) commands to
move the transfer case shift sector bi-directionally, as
required, to obtain the transfer case operating mode
indicated by the instrument panel mounted selector
switch.
REMOVAL
(1) Raise the vehicle on a suitable hoist.
(2) Disengage the wiring connectors from the shift
motor and mode sensor.
(3) Remove the bolts holding the shift motor and
mode sensor assembly onto the transfer case.
(4) Separate the shift motor and mode sensor
assembly from the transfer case.
INSTALLATION
(1) Verify that the shift sector o-ring is clean and
properly positioned over the shift sector and against
the transfer case.
(2) Position the shift motor and mode sensor
assembly onto the transfer case.
(3) Install the bolts to hold the assembly onto the
transfer case. Tighten the bolts to 16-24 N´m (12-18
ft.lbs.).
CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
MoparTLock & Seal or LoctiteŸ 242 to replenish
the lock patch material originally found on the bolts
(4) Engage the wiring connectors to the shift motor
and mode sensor.
(5) Refill the transfer case as necessary.
(6) Lower vehicle and verify transfer case opera-
tion.
Fig. 85 Shift Motor - Shown Inverted - Typical
1 - SHIFT MOTOR
21 - 686 TRANSFER CASE - NV243DR
SELECTOR SWITCH (Continued)