DODGE RAM 2003 Service Repair Manual

(19) Remove front band reaction pin and lever.
Start pin through lever and out of case bore with
drift or punch. Then use pencil magnet to withdraw
pin completely (Fig. 33).
(20) Remove intermediate shaft thrust washer. Tri-
angular shaped washer will either be on shaft pilot
hub or in rear clutch retainer (Fig. 34).
(21) Remove thrust plate from intermediate shaft
hub (Fig. 35).
(22) Remove intermediate shaft-planetary
geartrain assembly (Fig. 36).
(23) If overdrive unit is not to be serviced, install
Alignment Shaft 6227-2 into the overdrive unit to
prevent misalignment of the overdrive clutches dur-
ing service of main transmission components.
(24) Loosen rear band locknut and loosen adjust-
ing screw 3-4 turns.
Fig. 33 Front Band Lever And Pin
1 - BAND LEVER
2 - USE PENCIL MAGNET TO REMOVE REACTION PIN
Fig. 34 Intermediate Shaft Thrust Washer
1 - THRUST WASHER
2 - INTERMEDIATE SHAFT PILOT HUB
Fig. 35 Intermediate Shaft Thrust Plate
1 - SHAFT THRUST PLATE
2 - INTERMEDIATE SHAFT PILOT HUB
Fig. 36 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEARTRAIN
ASSEMBLY
21 - 162 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

(25) Remove snap-ring that retains low-reverse
drum on overdrive piston retainer hub (Fig. 37).
(26) Slide low-reverse drum and thrust washer off
piston retainer hub and out of rear band (Fig. 38).(27) Note that overrunning clutch race will remain
on splines of low-reverse drum after removal (Fig.
39).The race is a permanent press fit on the
hub splines. Do not attempt to remove the race.
(28) Remove overrunning clutch assembly (Fig.
40). Assembly can be removed without displacing
rollers and springs if care is exercised. Note position
of rollers and springs for assembly reference.
Fig. 38 Low-Reverse Drum And Thrust Washer
1 - LOW-REVERSE DRUM
2 - SPOTFACE FOR WASHER
3 - THRUST WASHER
Fig. 39 Overrunning Clutch Race Position On
Low-Reverse Drum
1 - OVERRUNNING CLUTCH RACE
2 - LOW-REVERSE DRUM
Fig. 40 Overrunning Clutch Removal
1 - CLUTCH CAM
2 - OVERRUNNING CLUTCH ASSEMBLY
Fig. 37 Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - TABBED WASHER
3 - SNAP-RING
DRAUTOMATIC TRANSMISSION - 46RE 21 - 163
AUTOMATIC TRANSMISSION - 46RE (Continued)

(29) Remove rear band adjusting lever, reaction
lever and pin (Fig. 41).
(30) Remove strut from rear band. Keep strut with
levers and pin for cleaning, inspection and assembly
reference.
(31) Remove rear band and link (Fig. 42).(32) Compress front servo rod guide with large
C-clamp and Tool C-4470, or Compressor Tool
C-3422-B (Fig. 43). Compress guide only enough to
permit snap-ring removal (about 1/8 in.).
(33) Remove servo piston snap-ring (Fig. 43).
Unseat one end of ring. Then carefully work removal
tool around back of ring until free of ring groove.
Exercise caution when removing snap-ring.
Servo bore can be scratched or nicked if care is
not exercised.
(34) Remove tools and remove servo piston and
spring.
(35) Compress rear servo piston with C-clamp and
Tool C-4470, or Valve Spring Compressor C-3422-B
(Fig. 44). Compress servo spring retainer only
enough to permit snap-ring removal.
(36) Remove servo piston snap-ring (Fig. 44). Start
one end of ring out of bore. Then carefully work
removal tool around back of snap-ring until free of
ring groove.Exercise caution when removing
snap-ring. Servo bore can be scratched or
nicked if care is not exercised.
(37) Remove tools and remove rear servo retainer,
spring and piston assembly.
CLEANING
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.
Fig. 41 Rear Band Levers And Pins
1 - REAR BAND ADJUSTING LEVER
2 - REACTION LEVER
3 - BAND LINK
4 - REAR BAND REACTION PIN
Fig. 42 Rear Band And Link
1 - BAND LINK
2 - REAR BAND
Fig. 43 Front Servo Retaining Snap-Ring
1 - C-CLAMP
2 - FRONT SERVO ROD GUIDE
3 - SNAP-RING
4 - TOOL C-4470
21 - 164 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

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.
Lubricate transmission parts with MopartATF +4,
Automatic Transmission fluid during overhaul and
assembly. Use petroleum jelly to prelubricate seals,
O-rings, and thrust washers. Petroleum jelly can also
be used to hold parts in place during reassembly.
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.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
Inspect the transmission bushings during overhaul.
Bushing condition is important as worn, scored bush-
ings contribute to low pressures, clutch slip and
accelerated wear of other components. However, do
not replace bushings as a matter of course. Replace
bushings only when they are actually worn, or
scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install, and
seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B.Pre-sized service bushings are available for
replacement purposes. Only the sun gear bushings
are not serviced.
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
ASSEMBLY
Do not allow dirt, grease, or foreign material to
enter the case or transmission components during
assembly. Keep the transmission case and compo-
nents clean. Also make sure the tools and workbench
area used for reassembly operations are equally
clean.
Shop towels used for wiping off tools and your
hands must be made fromlint freematerials. Lint
will stick to transmission parts and could interfere
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear compo-
nents with MopartATF +4, Automatic Transmission
fluid, during reassembly. Soak clutch discs in trans-
mission fluid before installation.
Use MopartDoor Ease, or Ru-GlydeŸ on piston
seals and O-rings to ease installation. Petroleum jelly
can also be used to lubricate and hold thrust washers
and plates in position during assembly.
Do not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of lubricants can eventually block or
restrict fluid passages and valve operation. Use
petroleum jelly only.
Do not force parts into place. The transmission
components and sub-assemblies are easily installed
by hand when properly aligned. If a part seems dif-
ficult to install, it is either misaligned or incorrectly
assembled. Verify that thrust washers, thrust plates
and seal rings are correctly positioned.
The planetary geartrain, front/rear clutch assem-
blies and oil pump are all much easier to install
when the transmission case is upright. Either tilt the
case upward with wood blocks, or cut a hole in the
bench large enough for the intermediate shaft and
rear support. Then lower the shaft and support into
the hole and support the rear of the case directly on
the bench.Fig. 44 Rear Servo Retaining Snap-Ring
1 - TOOL C-4470
2 - C-CLAMP
3 - REAR SERVO SPRING RETAINER
4 - RETAINER SNAP-RING
DRAUTOMATIC TRANSMISSION - 46RE 21 - 165
AUTOMATIC TRANSMISSION - 46RE (Continued)

FRONT/REAR SERVO
(1) Lubricate rear servo piston seal with Mopart
Door Ease or ATF +4. Lubricate servo bore in case
with ATF +4.
(2) Install rear servo piston in case. Position piston
at slight angle to bore and insert piston with twisting
motion (Fig. 45).
(3) Install rear servo spring and retainer in case
bore (Fig. 46). Be sure spring is seated on piston.
(4) Compress rear servo piston with C-clamp or
Valve Spring Compressor C-3422-B and install servo
piston snap-ring (Fig. 47).(5) Lubricate front servo piston components and
servo bore in case with transmission fluid.
(6) Install front servo piston in bore. Carefully
ªrunº small, suitable tool around piston ring to press
it back into groove and ease installation (Fig. 48).
Rotate piston into bore at same time. Rock piston
slightly to ease piston ring past snap-ring groove and
into bore.
Fig. 45 Rear Servo Piston
1 - REAR SERVO PISTON
Fig. 46 Rear Servo Piston Spring And Retainer
1 - PISTON SPRING
2 - REAR SERVO PISTON
3 - SPRING RETAINER
Fig. 47 Rear Servo Snap-Ring
1 - TOOL C-4470
2 - C-CLAMP
3 - REAR SERVO SPRING RETAINER
4 - RETAINER SNAP-RING
Fig. 48 Front Servo Piston
1 - USE SUITABLE TOOL TO HELP SEAT PISTON RING
2 - FRONT SERVO PISTON
21 - 166 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

(7) Bottom front servo piston in bore and install
servo spring.
(8) Install front servo piston rod guide as follows:
(a) Place Tool SP-5560 (or similar size tool) on
guide and position C-clamp on tool and case (Fig.
49).
(b) Slowly compress rod guide while simulta-
neously easing seal ring into bore with suitable
tool.
(9) Install rod guide snap-ring (Fig. 49).
OVERRUNNING CLUTCH, REAR BAND, AND
LOW-REVERSE DRUM
(1) Install overrunning clutch components.
(2) Position rear band and link in case (Fig. 50).
(3) Install low-reverse drum (Fig. 51). Slide drum
through rear band, onto piston retainer hub and into
engagement with overrunning clutch and race.
Fig. 49 Front Servo Rod Guide And Snap-Ring
1 - C-CLAMP
2 - ROD GUIDE
3 - SMALL SCREWDRIVER
4 - ROD GUIDE SNAP-RING
5 - TOOL SP-5560
Fig. 50 Rear Band And Link
1 - REAR BAND
2 - BAND LINK
Fig. 51 Low-Reverse Drum
1 - LOW-REVERSE DRUM
2 - REAR BAND LINK
3 - HUB OF OVERDRIVE PISTON RETAINER
DRAUTOMATIC TRANSMISSION - 46RE 21 - 167
AUTOMATIC TRANSMISSION - 46RE (Continued)

(4) Install thrust washer in low-reverse drum spot-
face (Fig. 52). Use petroleum jelly to hold washer in
place.
(5) Install snap-ring that secures low-reverse drum
to piston retainer hub (Fig. 52).
(6) Insert band reaction pin part way into case and
band link (Fig. 53).
(7) Install rear band adjusting lever, reaction lever,
and strut (Fig. 54). Be sure levers and strut are
aligned and engaged before seating band reaction pin
in case.
PLANETARY GEARTRAIN, FRONT/REAR CLUTCH,
AND FRONT BAND
(1) Remove Alignment Shaft 6227-2, if installed
previously.
(2) Install assembled intermediate shaft and plan-
etary geartrain (Fig. 55). Support shaft carefully dur-
ing installation. Do not allow shaft bearing/bushing
surfaces to become nicked or scratched.
Fig. 55 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEARTRAIN
ASSEMBLY
Fig. 52 Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - TABBED WASHER
3 - SNAP-RING
Fig. 53 Rear Band Reaction Pin
1 - REACTION PIN
2 - BAND LINK
3 - REAR BAND
4 - O-RINGS
Fig. 54 Rear Band Levers And Strut
1 - ADJUSTING SCREW AND NUT
2 - ADJUSTING LEVER
3 - REACTION LEVER
4 - STRUT
21 - 168 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

(3) Lubricate intermediate shaft thrust plate with
petroleum jelly and install plate on shaft pilot hub
(Fig. 56).
(4) Check input shaft front seal rings, fiber thrust
washer and rear seal ring (Fig. 57). Be ends of rear
seal ring are hooked together and the square cut
ends of front seal rings are firmly seated against
each other. Lubricate seal rings with petroleum jelly
after checking them.
(5) Assemble front and rear clutches (Fig. 58).
Align lugs on front clutch discs. Mount front clutch
on rear clutch. Turn front clutch retainer back and
forth until front clutch discs are fully seated on rear
clutch splined hub.
(6) Install intermediate shaft thrust washer in hub
of rear clutch retainer (Fig. 59). Use petroleum jelly
to hold washer in place. Position washer so grooves
are facing outward. Washer only fits one way in
clutch retainer hub.
(7) Place transmission case in upright position, or
place blocks under front end of transmission repair
stand to tilt case rearward. This makes it easier to
install front/rear clutch assembly.
(8) Align discs in rear clutch. Then install and
engage assembly in front planetary and driving shell
(Fig. 60). Turn clutch retainers back and forth until
both clutches are seated.
(9) Position front band lever in case and over servo
rod guide. Then install front band lever pin in case
and slide it through lever.
(10) Coat threads of front band pin access plug
with sealer and install it in case. Tighten plug to 17
N´m (13 ft. lbs.) torque.
Fig. 56 Intermediate Shaft Thrust Plate
1 - SHAFT THRUST PLATE
2 - INTERMEDIATE SHAFT PILOT HUB
Fig. 57 Input Shaft Seal Rings And Thrust Washer
1 - TORLONTFRONT SEAL RINGS
2 - INPUT SHAFT
3 - REAR SEAL RING
4 - THRUST WASHER
Fig. 58 Assembling Front And Rear Clutches
1 - FRONT CLUTCH ASSEMBLY
2 - REAR CLUTCH ASSEMBLY
3 - REAR CLUTCH SPLINED HUB
DRAUTOMATIC TRANSMISSION - 46RE 21 - 169
AUTOMATIC TRANSMISSION - 46RE (Continued)

(11) Slide front band over front clutch retainer and
install front band strut and anchor (Fig. 61).
(12) Tighten front band adjusting screw until band
is tight on clutch retainer. This will hold clutches in
place while oil pump is being installed. Verify that
front/rear clutch assembly is still properly seated
before tightening band.
OIL PUMP
(1) Install oil pump Pilot Studs C-3288-B in case
(Fig. 62).
(2) Install new oil pump gasket on pilot studs and
seat it in case. Be sure gasket is properly aligned
with fluid passages in case (Fig. 62).
(3) Coat the reaction shaft thrust washer with
petroleum jelly to hold it in place. Then install
washer over reaction shaft hub and seat it on pump
(Fig. 63).
CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
(4) Check seal rings on reaction shaft support. Be
sure rings are hooked together correctly. Also be sure
fiber thrust washer is in position (Fig. 64). Use extra
petroleum jelly to hold washer in place if necessary.
(5) Lubricate oil pump seals with petroleum
MopartATF +4.
Fig. 59 Intermediate Shaft Thrust Washer
1 - BE SURE WASHER GROOVES FACE OUT AS SHOWN
2 - REAR CLUTCH RETAINER HUB
3 - THRUST WASHER
Fig. 60 Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
Fig. 61 Front Band And Linkage
1 - LEVER
2 - STRUT
3 - ANCHOR
4 - FRONT BAND
21 - 170 AUTOMATIC TRANSMISSION - 46REDR
AUTOMATIC TRANSMISSION - 46RE (Continued)

(6) Mount oil pump on pilot studs and slide pump
into case opening (Fig. 65). Work pump into case by
hand. Do not use a mallet or similar tools to seat
pump.
(7) Remove pilot studs and install oil pump bolts.
Tighten pump bolts alternately and evenly to fully
seat pump in case. Then final-tighten pump bolts to
20 N´m (15 ft. lbs.) torque.
(8) Verify correct installation. Rotate input and
intermediate shafts and check for bind. If bind exists,
components are either mis-assembled, or not seated.
Disassemble and correct as necessary before proceed-
ing.
Fig. 62 Oil Pump Gasket And Pilot Studs
1 - OIL PUMP GASKET
2 - PILOT STUDS C-3288-B
Fig. 63 Reaction Shaft Thrust Washer
1 - THRUST WASHER
2 - CHAMFERED SIDE OF WASHER BORE GOES TOWARD
PUMP
Fig. 64 Reaction Shaft Seal Ring And Thrust Washer
1 - SEAL RINGS
2 - REACTION SHAFT SUPPORT
3 - THRUST WASHER (FIBER)
Fig. 65 Oil Pump
1 - SEAT OIL PUMP IN CASE BY HAND
2 - REMOVE PILOT STUDS WHEN PUMP IS SEATED
DRAUTOMATIC TRANSMISSION - 46RE 21 - 171
AUTOMATIC TRANSMISSION - 46RE (Continued)