clutch DODGE RAM 2003 Service Repair Manual

CONDITION POSSIBLE CAUSES CORRECTION
GROWLING, GRATING OR
SCRAPING NOISES1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands Mis-
adjusted.8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Mis-adjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Inspect pump
for excessive side clearance. Replace
pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.1. Test wiring and connectors with test lamp
and volt/ohmmeter. Repair wiring as
necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRBTscan
tool. Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRBTscan tool at PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid
if plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup
timing valve.
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AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO 4-3 DOWNSHIFT
WHEN CONTROL SWITCH
IS TURNED OFF1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.2. Test solenoids and replace if seized or
shorted.
3. PCM Malfunction. 3. Test with DRBTscan tool. Replace PCM
if faulty.
4. Valve Body Stuck Valves. 4. Repair stuck 3-4, lockup or lockup timing
valve.
CLUNK NOISE FROM
DRIVELINE ON CLOSED
THROTTLE 4-3
DOWNSHIFT1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Mis-adjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.3. Replace overdrive piston thrust plate
spacer.
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3
SHIFT1. Overdrive Solenoid Connector or
Wiring Shorted.1. Test connector and wiring for loose
connections, shorts or ground and repair as
needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary.
Check with DRBTscan tool.
3. PCM Malfunction. 3. Test PCM with DRBTscan tool and
replace controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect
valve body components. Make sure all
valves and plugs slide freely in bores.
Polish valves with crocus cloth if needed.
WHINE/NOISE RELATED
TO ENGINE SPEED1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
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AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.4. Check with DRBTscan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRBTscan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
7. PCM Malfunction. 7. Check with DRBTscan tool and replace
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRBTscan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
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AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
SLIPS IN OVERDRIVE
FOURTH GEAR1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild clutch
pack.
3. Overdrive Piston Retainer Bleed
Orifice Blown Out.3. Disassemble transmission, remove
retainer and replace orifice.
4. Overdrive Piston or Seal
Malfunction.4. Remove overdrive unit. Replace seals if
worn. Replace piston if damaged. If piston
retainer is damaged, remove and
disassemble the transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.5. Remove and overhaul valve body.
Replace accumulator seals. Make sure all
valves operate freely in bores and do not
bind or stick. Make sure valve body screws
are correctly tightened and separator plates
are properly positioned.
6. Overdrive Unit Thrust Bearing
Failure.6. Disassemble overdrive unit and replace
thrust bearing (NO. 1 thrust bearing is
between overdrive piston and clutch hub;
NO. 2 thrust bearing is between the
planetary gear and the direct clutch spring
plate; NO. 3 thrust bearing is between
overrunning clutch hub and output shaft).
7. O/D Check Valve/Bleed Orifice
Failure.7. Check for function/secure orifice insert in
O/D piston retainer.
DELAYED 3-4 UPSHIFT
(SLOW TO ENGAGE)1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Throttle Valve Cable Mis-adjusted. 2. Adjust throttle valve cable.
3. Overdrive Clutch Pack Worn/
Burnt.3. Remove unit and rebuild clutch pack.
4. TPS Faulty. 4. Test with DRBTscan tool and replace as
necessary
5. Overdrive Clutch Bleed Orifice
Plugged.5. Disassemble transmission and replace
orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.6. Test solenoid and check wiring for
loose/corroded connections or shorts/
grounds. Replace solenoid if faulty and
repair wiring if necessary.
7. Overdrive Excess Clearance. 7. Remove unit. Measure end play and
select proper spacer.
8. O/D Check Valve Missing or
Stuck.8. Check for presence of check valve.
Repair or replace as required.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEARLockup Solenoid, Relay or Wiring
Shorted/Open.Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2, 2-3, 3-4 OR
3-2 SHIFTSLockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
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AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO START IN PARK OR
NEUTRAL1. Gearshift Linkage/Cable
Mis-adjusted.1. Adjust linkage/cable.
2. Neutral Sense Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Park/Neutral Switch, or
Transmission Range Sensor Faulty.3. Refer to service section for test and
replacement procedure.
4. Park/Neutral Switch, or
Transmission Range Sensor
Connection Faulty.4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.5. Inspect lever assembly and replace if
damaged.
NO REVERSE (OR SLIPS
IN REVERSE)1. Direct Clutch Pack (front clutch)
Worn.1. Disassemble unit and rebuild clutch
pack.
2. Rear Band Mis-adjusted. 2. Adjust band.
3. Front Clutch Malfunctioned/
Burned.3. Air-pressure test clutch operation.
Remove and rebuild if necessary.
4. Overdrive Thrust Bearing Failure. 4. Disassemble geartrain and replace
bearings.
5. Direct Clutch Spring Collapsed/
Broken.5. Remove and disassemble unit. Check
clutch position and replace spring.
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AUTOMATIC TRANSMISSION - 48RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS. 1. Fluid Lines and Fittings Loose/
Leaks/Damaged.1. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
2. Fill Tube (where tube enters case)
Leaks/Damaged.2. Replace tube seal. Inspect tube for
cracks in fill tube.
3. Pressure Port Plug Loose
Loose/Damaged.3. Tighten to correct torque. Replace plug
or reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.5. Replace shaft seal.
6. Rear Bearing Access Plate Leaks. 6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.8. Replace gasket.
9. Park/Neutral Switch, or
Transmission Range Sensor
Leaks/Damaged.9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION IN
FOURTH GEAR ONLY1. Overdrive Clutch Discs, Plates or
Snap Rings Damaged.1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.2. Remove and disassemble unit. Replace
either thrust bearing if damaged.
3. Output Shaft Bearings Scored/
Damaged.3. Remove and disassemble unit. Replace
either bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning Clutch
Rollers Worn/Scored.5. Remove and overhaul overdrive unit.
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AUTOMATIC TRANSMISSION - 48RE (Continued)

(11) Remove pump oil seal with suitable pry tool or
slide-hammer mounted screw.
(12) Remove front band lever pin access plug (Fig.
25). Use square end of 1/4 in. drive extension to
remove plug as shown.
(13) Remove oil pump and reaction shaft support
assembly as follows:
(a) Tighten front band adjusting screw until
band is tight around front clutch retainer (Fig. 26).
This will prevent retainer from coming out with
pump and possibly damaging clutch or pump com-
ponents.
(b) Remove oil pump bolts.(c) Thread Slide Hammer Tools C-3752 into
threaded holes in flange of oil pump housing (Fig.
27).
(d) Remove oil pump and reaction shaft support
by bumping slide hammers outward alternately to
pull pump from case (Fig. 28).
Fig. 26 Tightening Front Band To Hold Front Clutch
In Place
1 - LOCK-NUT
2 - FRONT BAND ADJUSTER
Fig. 27 Oil Pump Removal Tools
1 - PUMP HOUSING
2 - SLIDE HAMMER TOOLS (THREAD INTO PUMP HOUSING)
Fig. 28 Oil Pump Removal
1 - OIL PUMP AND REACTION SHAFT SUPPORT
Fig. 25 Front Band Lever Pin Access Plug
1 - FRONT BAND REACTION PIN ACCESS PLUG
2 - 1/4 DRIVE EXTENSION AND RATCHET
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AUTOMATIC TRANSMISSION - 48RE (Continued)

(14) Remove oil pump gasket (Fig. 29). Note gas-
ket position in case for assembly reference.
(15) Loosen front band adjusting screw until band
is completely loose.
(16) Remove front band strut and anchor (Fig. 30).
(17) Squeeze front band together slightly and slide
band over front clutch retainer and out of case (Fig.
31).
(18) Remove front and rear clutch assemblies as a
unit (Fig. 32).
Fig. 32 Removing Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
Fig. 29 Oil Pump Gasket
1 - OIL PUMP GASKET
Fig. 30 Front Band Linkage
1 - LEVER
2 - STRUT
3 - ANCHOR
4 - FRONT BAND
Fig. 31 Front Band Removal
1 - FRONT BAND
2 - FRONT CLUTCH RETAINER
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AUTOMATIC TRANSMISSION - 48RE (Continued)

(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.
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 GEAR TRAIN
ASSEMBLY
DRAUTOMATIC TRANSMISSION - 48RE 21 - 343
AUTOMATIC TRANSMISSION - 48RE (Continued)

(24) Loosen rear band locknut and loosen adjust-
ing screw 3-4 turns.
(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.(29) Remove rear band adjusting lever and reac-
tion pin.
(30) Remove rear band.
Fig. 38 Low-Reverse Drum And Thrust Washer
1 - LOW-REVERSE DRUM
2 - SPOTFACE FOR WASHER
3 - THRUST WASHER
Fig. 37 Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - TABBED WASHER
3 - SNAP-RING
Fig. 39 Overrunning Clutch Race Position On
Low-Reverse Drum
1 - OVERRUNNING CLUTCH RACE
2 - LOW-REVERSE DRUM
Fig. 40 Overrunning Clutch
1 - CLUTCH CAM
2 - OVERRUNNING CLUTCH ASSEMBLY
21 - 344 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)