clutch DODGE RAM 2003 Service Repair Manual

MANUAL VALVE
The manual valve (Fig. 288) is a relay valve. The
purpose of the manual valve is to direct fluid to the
correct circuit needed for a specific gear or driving
range. The manual valve, as the name implies, is
manually operated by the driver with a lever located
on the side of the valve body. The valve is connected
mechanically by either a cable or linkage to the gear-
shift mechanism. The valve is held in each of its
positions by a spring-loaded roller or ball that
engages the ªroostercombº of the manual valve lever.
CONVERTER CLUTCH LOCK-UP VALVE
The torque converter clutch (TCC) lock-up valve
controls the back (ON) side of the torque converter
clutch. When the PCM energizes the TCC solenoid to
engage the converter clutch piston, pressure is
applied to the TCC lock-up valve which moves to the
right and applies pressure to the torque converter
clutch.
CONVERTER CLUTCH LOCK-UP TIMING VALVE
The torque converter clutch (TCC) lock-up timing
valve is there to block any 4-3 downshift until the
TCC is completely unlocked and the clutch is disen-
gaged.
SHUTTLE VALVE
The assembly is contained in a bore in the valve
body above the shift valves. When the manual valve
is positioned in the Drive range, throttle pressure
acts on the throttle plug of the shuttle valve (Fig.
280) to move it against a spring, increasing the
spring force on the shuttle valve. During a part or
full throttle 1-2 upshift, the throttle plug is bottomed
by throttle pressure, holding the shuttle valve to the
right against governor pressure, and opening a
by±pass circuit. The shuttle valve controls the qual-
ity of the kickdown shift by restricting the rate of
fluid discharge from the front clutch and servo
release circuits. During a 3-2 kickdown, fluid dis-
charges through the shuttle by-pass circuit. When
the shuttle valve closes the by-pass circuit, fluid dis-
charge is restricted and controlled for the application
of the front band. During a 2-3 ªlift footº upshift, the
shuttle valve by-passes the restriction to allow full
fluid flow through the by-pass groove for a faster
release of the band.
Fig. 288 Manual Valve
DRAUTOMATIC TRANSMISSION - 46RE 21 - 285
VALVE BODY (Continued)

BOOST VALVE
The boost valve (Fig. 289) provides increased fluid
apply pressure to the overdrive clutch during 3-4
upshifts (Fig. 290), and when accelerating in fourth
gear. The boost valve also serves to increase line
pressure during torque converter lock-up.
REMOVAL
The valve body can be removed for service without
having to remove the transmission assembly.
The valve body can be disassembled for cleaning
and inspection of the individual components.
The only replaceable valve body components are:
²Manual lever.
²
Manual lever washer, seal, E-clip, and shaft seal.
²Manual lever detent ball.
²Throttle lever.
²Fluid filter.
²Pressure adjusting screw bracket.
²Governor pressure solenoid.
²Governor pressure sensor (includes transmission
temperature thermistor).
²Converter clutch/overdrive solenoid assembly
and harness.
²Governor housing gasket.
²Solenoid case connector O-rings.
(1) Shift transmission into NEUTRAL.
(2) Raise vehicle.
(3) Remove gearshift and throttle levers from shaft
of valve body manual lever.
(4) Disconnect wires at solenoid case connector
(Fig. 291).
(5) Remove the transmission range sensor.
(6) Position drain pan under transmission oil pan.
(7) Remove transmission oil pan and gasket.
(8) Remove fluid filter from valve body.
(9) Remove bolts attaching valve body to transmis-
sion case.
(10) Lower valve body enough to remove accumu-
lator piston and springs.
(11) Work manual lever shaft and electrical con-
nector out of transmission case.
Fig. 291 Transmission Case Connector
1 - SOLENOID CASE CONNECTOR
2 - TRANSMISSION RANGE SENSOR
Fig. 289 Boost Valve Before Lock-up
Fig. 290 Boost Valve After Lock-up
21 - 286 AUTOMATIC TRANSMISSION - 46REDR
VALVE BODY (Continued)

(8) Turn valve body over and remove screws that
attach overdrive/converter solenoid assembly to valve
body (Fig. 295).
(9) Remove solenoid and harness assembly from
valve body (Fig. 296).
(10) Remove boost valve cover (Fig. 297).
(11) Remove boost valve retainer, valve spring and
boost valve (Fig. 298).
(12) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 299).
Fig. 299 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 295 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 296 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 297 Boost Valve Cover Location
1 - BOOST VALVE HOUSING AND COVER
2 - BOOST VALVE TUBE
Fig. 298 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
21 - 288 AUTOMATIC TRANSMISSION - 46REDR
VALVE BODY (Continued)

(22) Carefully rotate 3-4 accumulator housing
upward and remove 3-4 shift valve spring and con-
verter clutch valve plug and spring (Fig. 308).
Fig. 306 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
Fig. 307 Accumulator Housing Screw Locations
1 - LOOSEN THIS SCREW
2 - REMOVE THESE SCREWS
3 - 3-4 ACCUMULATOR HOUSINGFig. 308 3-4 Shift And Converter Clutch Valve
Springs and Plug
1 - ACCUMULATOR HOUSING
2 - CONVERTER CLUTCH VALVE SPRING
3 - CLUTCH VALVE PLUG
4 - 3-4 SHIFT VALVE SPRING
DRAUTOMATIC TRANSMISSION - 46RE 21 - 291
VALVE BODY (Continued)

(23) Remove left-side screw and remove 3-4 accu-
mulator housing from valve body (Fig. 309).
(24) Bend back tabs on boost valve tube brace (Fig.
310).
(25) Remove boost valve connecting tube (Fig. 311).
Disengage tube from upper housing port first. Then
rock opposite end of tube back and forth to work it
out of lower housing.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.(26) Turn valve body over so lower housing is fac-
ing upward (Fig. 312). In this position, the two check
balls in upper housing will remain in place and not
fall out when lower housing and separator plate are
removed.
(27) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
312). Note position of boost valve tube brace for
assembly reference.
(28) Remove lower housing and overdrive separa-
tor plate from transfer plate (Fig. 312).
Fig. 311 Boost Valve Tube
1 - BOOST VALVE TUBE
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 312 Lower Housing
1 - LOWER HOUSING
2 - OVERDRIVE SEPARATOR PLATE
3 - TRANSFER PLATE AND UPPER HOUSING
Fig. 309 Accumulator Housing, Valve Springs, and
Plug
1 - 3-4 SHIFT VALVE SPRING
2 - CONVERTER CLUTCH VALVE SPRING AND PLUG
3 - 3-4 ACCUMULATOR HOUSING
Fig. 310 Boost Valve Tube Brace
1 - BOOST VALVE TUBE
2 - TUBE BRACE (DOUBLE TAB)
21 - 292 AUTOMATIC TRANSMISSION - 46REDR
VALVE BODY (Continued)

(29) Remove the Number 10 check ball from the
transfer plate (Fig. 313). The check ball is approxi-
mately 4.8 mm (3/16 in.) in diameter.
(30) Remove transfer plate from upper housing
(Fig. 314).
(31) Turn transfer plate over so upper housing sep-
arator plate is facing upward.(32) Remove upper housing separator plate from
transfer plate (Fig. 315). Note position of filter in
separator plate for assembly reference.
(33) Remove rear clutch and rear servo check balls
from transfer plate. Note check ball location for
assembly reference (Fig. 316).
Fig. 313 Number 10 Check Ball
1 - NUMBER 10 CHECK BALL (3/169)
Fig. 314 Transfer Plate
1 - UPPER HOUSING
2 - TRANSFER PLATE
Fig. 315 Upper Housing Separator Plate
1 - TRANSFER PLATE
2 - UPPER HOUSING SEPARATOR PLATE
3 - FILTER SCREEN
4 - BRACE
Fig. 316 Rear Clutch and Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
DRAUTOMATIC TRANSMISSION - 46RE 21 - 293
VALVE BODY (Continued)

VALVE BODY UPPER HOUSING
(1) Note location of check balls in valve body upper
housing (Fig. 317). Then remove the one large diam-
eter and the six smaller diameter check balls.
(2) Remove governor plug and shuttle valve covers
(Fig. 319).
(3) Remove E-clip that secures shuttle valve sec-
ondary spring on valve stem (Fig. 318).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 319).
(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. 306).
(7) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 320).
(8) Remove limit valve housing. Then remove
retainer, spring, limit valve, and 2-3 throttle plug
from limit valve housing (Fig. 320).
(9) Remove 1-2 shift control valve and spring (Fig.
320).
(10) Remove 1-2 shift valve and spring (Fig. 320).
(11) Remove 2-3 shift valve and spring from valve
body (Fig. 320).
(12) Remove pressure plug cover (Fig. 320).
(13) Remove line pressure plug, sleeve, throttle
pressure plug and spring (Fig. 320).
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. 321).
(6) Remove converter clutch timing valve, retainer
and valve spring.
3-4 ACCUMULATOR HOUSING
(1) Remove end plate from housing.
(2) Remove piston spring.
(3) Remove piston. Remove and discard piston
seals (Fig. 322).
Fig. 317 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (6)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 318 Shuttle Valve E-Clip And Secondary Spring
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
21 - 294 AUTOMATIC TRANSMISSION - 46REDR
VALVE BODY (Continued)

Fig. 321 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 - 46RE 21 - 297
VALVE BODY (Continued)

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-clip
ASSEMBLY
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. 321).
(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.
3-4 ACCUMULATOR
(1) Lubricate accumulator piston, seals and hous-
ing piston bore with clean transmission fluid (Fig.
322).
(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. 323).
(2) Install filter screen in upper housing separator
plate (Fig. 324).
Fig. 323 Rear Clutch And Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
Fig. 324 Separator Plate Filter Screen Installation
1 - UPPER HOUSING SEPARATOR PLATE
2 - FILTER SCREEN
DRAUTOMATIC TRANSMISSION - 46RE 21 - 299
VALVE BODY (Continued)

3-4 ACCUMULATOR
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 337).
(2) Loosely attach accumulator housing with right-
side screw (Fig. 337). Install only one screw at this
time as accumulator must be free to pivot upward for
ease of installation.
(3) Install 3-4 shift valve and spring.
(4) Install converter clutch timing valve and
spring.(5) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(6) Swing accumulator housing upward over valve
springs and plug.
(7) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated
(Fig. 338). Tighten screws to 4 N´m (35 in. lbs.).
Fig. 335 Boost Valve Tube And Brace
1 - BOOST VALVE TUBE
2 - TUBE BRACE
Fig. 336 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
Fig. 337 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
3 - 3-4 SHIFT VALVE SPRING
4 - CONVERTER CLUTCH VALVE SPRING
Fig. 338 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
DRAUTOMATIC TRANSMISSION - 46RE 21 - 305
VALVE BODY (Continued)