DODGE RAM 2003 Service Repair Manual

VALVE BODY UPPER HOUSING
(1) Note location of check balls in valve body upper
housing (Fig. 301). Then remove the one large diam-
eter and the five smaller diameter check balls.
(2) Remove governor plug and shuttle valve covers
(Fig. 303).
(3) Remove E-clip that secures shuttle valve sec-
ondary spring on valve stem (Fig. 302).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 303).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
(6) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 290).
(7) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 304).
(8) Remove limit valve housing. Then remove
retainer, spring, limit valve, and 2-3 throttle plug
from limit valve housing (Fig. 304).
(9) Remove 1-2 shift control valve and spring (Fig.
304).
(10) Remove 1-2 shift valve and spring (Fig. 304).
(11) Remove 2-3 shift valve and spring from valve
body (Fig. 304).
(12) Remove pressure plug cover (Fig. 304).
(13) Remove line pressure sleeve, throttle pressure
plug and spring (Fig. 304).
Fig. 301 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (5)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 302 Shuttle Valve E-Clip And Secondary Spring
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
21 - 472 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

Fig. 303 Shuttle and Boost Valve Location
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 473
VALVE BODY (Continued)

Fig. 304 Upper Housing Shift Valve and Pressure Plug Locations
1 - UPPER HOUSING 7 - LIMIT VALVE AND SPRING
2 - 1-2 SHIFT VALVE AND SPRING 8 - RETAINER
3 - 2-3 SHIFT VALVE AND SPRING 9 - 1-2 SHIFT CONTROL VALVE AND SPRING
4 - 2-3 THROTTLE PLUG 10 - PRESSURE PLUG COVER
5 - LIMIT VALVE HOUSING 11 - PLUG SLEEVE
6 - LIMIT VALVE COVER 12 - THROTTLE PRESSURE SPRING AND PLUG
21 - 474 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

VALVE BODY LOWER HOUSING
(1) Remove timing valve cover.
(2) Remove 3-4 timing valve and spring.
(3) Remove 3-4 quick fill valve, spring and plug.
(4) Remove 3-4 shift valve and spring.
(5) Remove converter clutch valve, spring and plug
(Fig. 305).
(6) Remove converter clutch timing valve, retainer
and valve spring.
Fig. 305 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
DRAUTOMATIC TRANSMISSION - 48RE 21 - 475
VALVE BODY (Continued)

3-4 ACCUMULATOR HOUSING
(1) Remove end plate from housing.
(2) Remove piston spring.
(3) Remove piston. Remove and discard piston
seals (Fig. 306).
CLEANING
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution.
Do not immerse any of the electrical components in
cleaning solution. Clean the governor solenoid and
sensor and the dual solenoid and harness assembly
by wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions.Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Wipe the governor pressure sensor and solenoid
valve with dry, lint free shop towels only. The O-rings
on the sensor and solenoid valve are the only service-
able components. Be sure the vent ports in the sole-
noid valve are open and not blocked by dirt or debris.
Replace the valve and/or sensor only when DRB scan
tool diagnosis indicates this is necessary. Or, if eitherpart has sustained physical damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of
the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
INSPECTION
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-
face. If distortion is severe or any surfaces are
heavily scored, the valve body will have to be
replaced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth
butdo not round off the edges of the valve or
plug lands.Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Fig. 306 3-4 Accumulator and Housing
1 - ACCUMULATOR PISTON
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
21 - 476 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

Check the two separator plates for distortion or
damage of any kind. Inspect the upper housing,
lower housing, 3-4 accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean
and clear. Check condition of the upper housing and
transfer plate check balls as well. The check balls
and ball seats must not be worn or damaged.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with
use. If the valve body functioned correctly when new,
it will continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
The only serviceable valve body components are
listed below. The remaining valve body components
are serviced only as part of a complete valve body
assembly. Serviceable parts are:
²dual solenoid and harness assembly
²solenoid gasket
²solenoid case connector O-rings and shoulder
bolt
²switch valve and spring
²pressure adjusting screw and bracket assembly
²throttle lever
²manual lever and shaft seal
²throttle lever shaft seal, washer, and E-clip
²fluid filter and screws
²detent ball and spring
²valve body screws
²governor pressure solenoid
²governor pressure sensor and retaining clip
²park lock rod and E-clipASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
LOWER HOUSING
(1) Lubricate valves, springs, and the housing
valve and plug bores with clean transmission fluid
(Fig. 307).
(2) Install 3-4 timing valve spring and valve in
lower housing.
(3) Install 3-4 quick fill valve in lower housing.
(4) Install 3-4 quick fill valve spring and plug in
housing.
(5) Install timing valve end plate. Tighten end
plate screws to 4 N´m (35 in. lbs.) torque.
DRAUTOMATIC TRANSMISSION - 48RE 21 - 477
VALVE BODY (Continued)

Fig. 307 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
21 - 478 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

3-4 ACCUMULATOR
(1) Lubricate accumulator piston, seals and hous-
ing piston bore with clean transmission fluid (Fig.
308).
(2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end plate on housing.
TRANSFER PLATE
(1) Install rear clutch and rear servo check balls in
transfer plate (Fig. 309).
(2) Install filter screen in upper housing separator
plate (Fig. 310).
(3) Align and position upper housing separator
plate on transfer plate (Fig. 311).
(4) Install brace plate (Fig. 311). Tighten brace
attaching screws to 4 N´m (35 in. lbs.) torque.
(5) Install remaining separator plate attaching
screws. Tighten screws to 4 N´m (35 in. lbs.) torque.
Fig. 308 3-4 Accumulator and Housing
1 - ACCUMULATOR PISTON
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
Fig. 309 Rear Clutch And Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
Fig. 310 Separator Plate Filter Screen Installation
1 - UPPER HOUSING SEPARATOR PLATE
2 - FILTER SCREEN
Fig. 311 Brace Plate
1 - BRACE
2 - TRANSFER PLATE
3 - SEPARATOR PLATE
DRAUTOMATIC TRANSMISSION - 48RE 21 - 479
VALVE BODY (Continued)

UPPER AND LOWER HOUSING
(1) Position upper housing so internal passages
and check ball seats are facing upward. Then install
check balls in housing (Fig. 312). Seven check balls
are used. The single large check ball is approxi-
mately 8.7 mm (11/32 in.) diameter. The single small
check ball is approximately 4.8 mm (3/16 in.) in
diameter. The remaining 5 check balls are approxi-
mately 6.3 mm (1/4 in.) in diameter.
(2) Position assembled transfer plate and upper
housing separator plate on upper housing (Fig. 313).
Be sure filter screen is seated in proper housing
recess.(3) Install the Number 10 check ball into the
transfer plate (Fig. 314). The check ball is approxi-
mately 4.8 mm (3/16 in.) in diameter.
(4) Position lower housing separator plate on
transfer plate (Fig. 315).
(5) Install lower housing on assembled transfer
plate and upper housing (Fig. 316).
(6) Install and start all valve body screws by hand
except for the screws to hold the boost valve tube
brace. Save those screws for later installation. Then
tighten screws evenly to 4 N´m (35 in. lbs.) torque.
Start at center and work out to sides when tighten-
ing screws (Fig. 316).
Fig. 312 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (5)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 313 Installing Transfer Plate On Upper Housing
1 - FILTER SCREEN
2 - TRANSFER PLATE/SEPARATOR PLATE ASSEMBLY
3 - UPPER HOUSING
Fig. 314 Number 10 Check Ball
1 - NUMBER 10 CHECK BALL (3/169)
Fig. 315 Lower Housing Separator Plate
1 - BE SURE TO ALIGN BORES
2 - TRANSFER PLATE
3 - LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
21 - 480 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

UPPER HOUSING VALVE AND PLUG
Refer to (Fig. 317), (Fig. 318) and (Fig. 319) to per-
form the following steps.
(1) Lubricate valves, plugs, springs with clean
transmission fluid.
(2) Assemble regulator valve line pressure sleeve,
throttle plug and spring. Insert assembly in upper
housing and install cover plate. Tighten cover plate
screws to 4 N´m (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install retainer, spring, limit valve, and 2-3
throttle plug from limit valve housing.
(6) Install limit valve housing and cover plate.
Tighten screws to 4 N´m (35 in. lbs.).
(7) Install shuttle valve as follows:
(a) Insert plastic guides in shuttle valve second-
ary spring and install spring on end of valve.
(b) Install shuttle valve into housing.
(c) Hold shuttle valve in place.
Fig. 316 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
Fig. 317 Shuttle and Boost Valve Locations
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 481
VALVE BODY (Continued)