DODGE RAM 2003 Service Repair Manual

OVERDRIVE CLUTCH PACK
(1) Remove overdrive clutch pack wire retaining
ring (Fig. 143).
(2) Remove overdrive clutch pack (Fig. 144).
(3) Note position of clutch pack components for
assembly reference (Fig. 145).
OVERDRIVE GEARTRAIN
(1) Remove overdrive clutch wave spring (Fig.
146).
(2) Remove overdrive clutch reaction snap-ring
(Fig. 147). Note that snap-ring is located in same
groove as wave spring.
Fig. 143 Removing Overdrive Clutch Pack Retaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 144 Overdrive Clutch Pack Removal
1 - OVERDRIVE CLUTCH PACK
Fig. 145 Overdrive Clutch Component Position -
Typical
1 - REACTION PLATE 3 - PRESSURE PLATE
2 - CLUTCH PLATES (3) 4 - CLUTCH DISCS (4)
Fig. 146 Overdrive Clutch Wave Spring Removal
1 - WAVE SPRING
Fig. 147 Overdrive Clutch Reaction Snap-Ring
Removal
1 - REACTION RING
2 - CLUTCH HUB
21 - 222 AUTOMATIC TRANSMISSION - 46REDR
OVERDRIVE UNIT (Continued)

(3) Remove TorxŸ head screws that attach access
cover and gasket to overdrive case (Fig. 148).
(4) Remove access cover and gasket (Fig. 149).
(5) Expand output shaft bearing snap-ring with
expanding-type snap-ring pliers. Then push output
shaft forward to release shaft bearing from locating
ring (Fig. 150).(6) Lift gear case up and off geartrain assembly
(Fig. 151).
(7) Remove snap-ring that retains rear bearing on
output shaft.
(8) Remove rear bearing from output shaft (Fig.
152).
Fig. 148 Access Cover Screw Removal
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 149 Access Cover And Gasket Removal
1 - ACCESS COVER AND GASKET
Fig. 150 Releasing Bearing From Locating Ring
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 151 Removing Geartrain
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 152 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
DRAUTOMATIC TRANSMISSION - 46RE 21 - 223
OVERDRIVE UNIT (Continued)

DIRECT CLUTCH, HUB AND SPRING
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT PROPER
EQUIPMENT BE USED TO COMPRESS THE SPRING AS
SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE
SPRING COMPRESSOR TOOL 6227-1 AND A HYDRAU-
LIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF
5-6 INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1)Mount geartrain assembly in shop press (Fig. 153).
(2) Position Compressor Tool 6227-1 on clutch hub
(Fig. 153). Support output shaft flange with steel
press plates as shown and center assembly under
press ram.
(3) Apply press pressure slowly. Compress hub and
spring far enough to expose clutch hub retaining ring
and relieve spring pressure on clutch pack snap-ring
(Fig. 153).(4) Remove direct clutch pack snap-ring (Fig. 154).
(5)
Remove direct clutch hub retaining ring (Fig. 155).
Fig. 153 Geartrain Mounted In Shop Press
1 - PRESS RAM
2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL)
3 - CLUTCH HUB
4 - PLATES
5 - PRESS BED
6 - SPECIAL TOOL 6227-1
Fig. 154 Direct Clutch Pack Snap-Ring Removal
1 - CLUTCH HUB
2 - SPECIAL TOOL 6227-1
3 - DIRECT CLUTCH PACK SNAP-RING
4 - PRESS PLATES
5 - CLUTCH DRUM
Fig. 155 Direct Clutch Hub Retaining Ring Removal
1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RING
3 - PRESS BED
4 - PRESS PLATES
21 - 224 AUTOMATIC TRANSMISSION - 46REDR
OVERDRIVE UNIT (Continued)

(6) Release press load slowly and completely (Fig.
156).
(7) Remove Special Tool 6227-1. Then remove
clutch pack from hub (Fig. 156).
GEARTRAIN
(1) Remove direct clutch hub and spring (Fig. 157).
(2) Remove sun gear and spring plate. Then
remove planetary thrust bearing and planetary gear
(Fig. 158).(3) Remove overrunning clutch assembly with
expanding type snap-ring pliers (Fig. 159). Insert pli-
ers into clutch hub. Expand pliers to grip hub splines
and remove clutch with counterclockwise, twisting
motion.
Fig. 159 Overrunning Clutch Assembly Removal/
Installation
1 - OVERRUNNING CLUTCH
2 - NEEDLE BEARING
Fig. 156 Direct Clutch Pack Removal
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH HUB
3 - DIRECT CLUTCH PACK
Fig. 157 Direct Clutch Hub And Spring Removal
1 - DIRECT CLUTCH SPRING
2 - DIRECT CLUTCH HUB
Fig. 158 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1 - PLANETARY GEAR
2 - PLANETARY THRUST BEARING
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 225
OVERDRIVE UNIT (Continued)

(4) Remove thrust bearing from overrunning
clutch hub.
(5) Remove overrunning clutch from hub.
(6) Mark position of annulus gear and direct clutch
drum for assembly alignment reference (Fig. 160).
Use small center punch or scriber to make alignment
marks.
(7) Remove direct clutch drum rear retaining ring
(Fig. 161).
(8) Remove direct clutch drum outer retaining ring
(Fig. 162).
(9) Mark annulus gear and output shaft for assem-
bly alignment reference (Fig. 163). Use punch or
scriber to mark gear and shaft.
Fig. 160 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 - DIRECT CLUTCH DRUM
2 - HAMMER
3 - PUNCH
Fig. 161 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
2 - DIRECT CLUTCH DRUM
3 - ANNULUS GEAR
Fig. 162 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 163 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
21 - 226 AUTOMATIC TRANSMISSION - 46REDR
OVERDRIVE UNIT (Continued)

(10) Remove snap-ring that secures annulus gear
on output shaft (Fig. 164). Use two screwdrivers to
unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig.
165). Use rawhide or plastic mallet to tap gear off
shaft.
GEAR CASE AND PARK LOCK
(1) Remove locating ring from gear case.
(2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap-ring and remove
reaction plug.
(4) Remove output shaft seal.
CLEANING
Clean the geartrain and case components with sol-
vent. Dry all parts except the bearings with com-
pressed air. Allow bearings to air dry.
Do not use shop towels for wiping parts dry unless
the towels are made from a lint-free material. A suf-
ficient quantity of lint (from shop towels, cloths, rags,
etc.) could plug the transmission filter and fluid pas-
sages.
Discard the old case gasket and seals. Do not
attempt to salvage these parts. They are not reus-
able. Replace any of the overdrive unit snap-rings if
distorted or damaged.
Minor nicks or scratches on components can be
smoothed with crocus cloth. However, do not attempt
to reduce severe scoring on any components with
abrasive materials. Replace severely scored compo-
nents; do not try to salvage them.
INSPECTION
Check condition of the park lock components and
the overdrive case.
Check the bushings in the overdrive case. Replace
the bushings if severely scored or worn. Also replace
the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and
plates. Replace the discs if the facing is worn,
severely scored, or burned and flaking off. Replace
the clutch plates if worn, heavily scored, or cracked.
Check the lugs on the clutch plates for wear. The
plates should slide freely in the drum. Replace the
plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch
hub, clutch drum and clutch spring. Replace the gear,
hub and drum if worn or damaged. Replace the
spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and
hub are in good condition. The clutch plates and
discs should slide freely in these components.
Inspect the thrust bearings and spring plate.
Replace the plate if worn or scored. Replace the bear-
ings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun
gear and bushings. If either the sun gear or the
bushings are damaged, replace the gear and bush-
ings as an assembly. The gear and bushings are not
serviced separately.
The planetary carrier and pinions must be in good
condition. Also be sure the pinion pins are secure and
in good condition. Replace the carrier if worn or dam-
aged.
Inspect the overrunning clutch and race. The race
surface should be smooth and free of scores. Replace
the overrunning clutch assembly or the race if either
assembly is worn or damaged in any way.
Fig. 164 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 165 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 227
OVERDRIVE UNIT (Continued)

Replace the shaft pilot bushing and inner bushing
if damaged. Replace either shaft bearing if rough or
noisy. Replace the bearing snap-rings if distorted or
cracked.
Check the machined surfaces on the output shaft.
These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Inspect the output shaft bushings. The small bush-
ing is the intermediate shaft pilot bushing. The large
bushing is the overrunning clutch hub bushing.
Replace either bushing if scored, pitted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak direct clutch and overdrive clutch discs in
MopartATF +4, Automatic Transmission fluid. Allow
discs to soak for 10-20 minutes.
(2) Install new pilot bushing and clutch hub bush-
ing in output shaft if necessary (Fig. 166). Lubricate
bushings with petroleum jelly, or transmission fluid.(3) Install annulus gear on output shaft, if
removed. Then install annulus gear retaining snap-
ring (Fig. 167).
(4) Align and install clutch drum on annulus gear
(Fig. 168). Be sure drum is engaged in annulus gear
lugs.
(5) Install clutch drum outer retaining ring (Fig.
168).
Fig. 166 Output Shaft Pilot Bushing
1 - OUTPUT SHAFT HUB
2 - OVERRUNNING CLUTCH HUB BUSHING
3 - INTERMEDIATE SHAFT PILOT BUSHING
Fig. 167 Annulus Gear Installation
1 - SNAP-RING
2 - OUTPUT SHAFT FRONT BEARING
3 - ANNULUS GEAR
Fig. 168 Clutch Drum And Outer Retaining Ring
Installation
1 - ANNULUS GEAR
2 - OUTER SNAP-RING
3 - CLUTCH DRUM
21 - 228 AUTOMATIC TRANSMISSION - 46REDR
OVERDRIVE UNIT (Continued)

(6) Slide clutch drum forward and install inner
retaining ring (Fig. 169).
(7) Install rear bearing and snap ring on output
shaft (Fig. 170). Be sure locating ring groove in bear-
ing is toward rear.
(8) Install overrunning clutch on hub (Fig. 171).
Note that clutch only fits one way. Shoulder on clutch
should seat in small recess at edge of hub.
(9) Install thrust bearing on overrunning clutch
hub. Use generous amount of petroleum jelly to hold
bearing in place for installation. Bearing fits one way
only. Be sure bearing is seated squarely against hub.
Reinstall bearing if it does not seat squarely.
(10) Install overrunning clutch in output shaft
(Fig. 172). Insert snap ring pliers in hub splines.
Expand pliers to grip hub. Then install assembly
with counterclockwise, twisting motion.
Fig. 172 Overrunning Clutch Installation
1 - CLUTCH DRUM
2 - OVERRUNNING CLUTCH ASSEMBLY
3 - EXPANDING-TYPE SNAP-RING PLIERS
4 - CLUTCH DRUM
5 - ANNULUS GEAR
6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
Fig. 169 Clutch Drum Inner Retaining Ring
Installation
1 - ANNULUS GEAR
2 - INNER SNAP-RING
3 - CLUTCH DRUM
Fig. 170 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
Fig. 171 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
2 - OVERRUNNING CLUTCH
DRAUTOMATIC TRANSMISSION - 46RE 21 - 229
OVERDRIVE UNIT (Continued)

(11) Install planetary gear in annulus gear (Fig.
173). Be sure planetary pinions are fully seated in
annulus gear before proceeding.
(12) Coat planetary thrust bearing and bearing
contact surface of spring plate with generous amount
of petroleum jelly. This will help hold bearing in
place during installation.
(13) Install planetary thrust bearing on sun gear
(Fig. 174). Slide bearing onto gear and seat it against
spring plate as shown. Bearing fits one way only. If it
does not seat squarely against spring plate, remove
and reposition bearing.
(14) Install assembled sun gear, spring plate and
thrust bearing (Fig. 175). Be sure sun gear and
thrust bearing are fully seated before proceeding.(15) Mount assembled output shaft, annulus gear,
and clutch drum in shop press. Direct clutch spring,
hub and clutch pack are easier to install with assem-
bly mounted in press.
(16) Align splines in hubs of planetary gear and
overrunning clutch with Alignment tool 6227-2 (Fig.
176). Insert tool through sun gear and into splines of
both hubs. Be sure alignment tool is fully seated
before proceeding.
Fig. 176 Alignment Tool Installation
1 - SPECIAL TOOL 6227-2
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
Fig. 173 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
Fig. 174 Planetary Thrust Bearing Installation
1 - SPRING PLATE
2 - PLANETARY THRUST BEARING
3 - SUN GEAR
Fig. 175 Sun Gear Installation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
21 - 230 AUTOMATIC TRANSMISSION - 46REDR
OVERDRIVE UNIT (Continued)

(17) Install direct clutch spring (Fig. 177). Be sure
spring is properly seated on spring plate.
NOTE: The direct clutch in a 46RE transmission
uses 8 clutch discs.
(18) Assemble and install direct clutch pack on
hub as follows:
(a) Assemble clutch pack components (Fig. 178).
(b) Install direct clutch reaction plate on clutch
hub first. Note that one side of reaction plate is
counterbored. Be sure this side faces rearward.Splines at rear of hub are raised slightly. Counter-
bore in plate fits over raised splines. Plate should
be flush with this end of hub (Fig. 179).
Fig. 178 46RE Direct Clutch Pack Components
1 - CLUTCH DISCS (8) 3 - CLUTCH PLATES (7)
2 - PRESSURE PLATE 4 - REACTION PLATE
Fig. 179 Correct Position Of Direct Clutch Reaction
Plate
1 - REACTION PLATE COUNTERBORE
2 - DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF
HUB)
3 - CLUTCH HUB
Fig. 177 Direct Clutch Spring Installation
1 - SPECIAL TOOL 6227-2
2 - DIRECT CLUTCH SPRING
3 - CLUTCH HUB
4 - PRESS PLATES
DRAUTOMATIC TRANSMISSION - 46RE 21 - 231
OVERDRIVE UNIT (Continued)