clutch DODGE RAM 2003 Service Repair Manual

(8) Remove direct clutch drum outer retaining ring
(Fig. 149).
(9) Mark annulus gear and output shaft for assem-
bly alignment reference (Fig. 150). Use punch or
scriber to mark gear and shaft.
(10) Remove snap-ring that secures annulus gear
on output shaft (Fig. 151). Use two screwdrivers to
unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig.
152). 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 suffi-
cient 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-
Fig. 149 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 150 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
Fig. 151 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 152 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
DRAUTOMATIC TRANSMISSION - 48RE 21 - 405
OVERDRIVE UNIT (Continued)

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 damaged.
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.
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 annulus gear on output shaft, if
removed. Then install annulus gear retaining snap-
ring (Fig. 153).
(3) Align and install clutch drum on annulus gear
(Fig. 154). Be sure drum is engaged in annulus gear
lugs.
(4) Install clutch drum outer retaining ring (Fig.
154).
Fig. 153 Annulus Gear Installation
1 - SNAP-RING
2 - OUTPUT SHAFT FRONT BEARING
3 - ANNULUS GEAR
Fig. 154 Clutch Drum And Outer Retaining Ring
Installation
1 - ANNULUS GEAR
2 - OUTER SNAP-RING
3 - CLUTCH DRUM
21 - 406 AUTOMATIC TRANSMISSION - 48REDR
OVERDRIVE UNIT (Continued)

(5) Slide clutch drum forward and install inner
retaining ring (Fig. 155).
(6) Install rear bearing and snap-ring on output
shaft (Fig. 156). Be sure locating ring groove in bear-
ing is toward rear.
(7) Install overrunning clutch on hub (Fig. 157).
Note that clutch only fits one way. Shoulder on clutch
should seat in small recess at edge of hub.
(8) 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.
(9) Install overrunning clutch in output shaft (Fig.
158). Insert snap-ring pliers in hub splines. Expand
pliers to grip hub. Then install assembly with coun-
terclockwise, twisting motion.
Fig. 158 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. 155 Clutch Drum Inner Retaining Ring
Installation
1 - ANNULUS GEAR
2 - INNER SNAP-RING
3 - CLUTCH DRUM
Fig. 156 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
Fig. 157 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
2 - OVERRUNNING CLUTCH
DRAUTOMATIC TRANSMISSION - 48RE 21 - 407
OVERDRIVE UNIT (Continued)

(10) Install planetary gear in annulus gear (Fig.
159). Be sure planetary pinions are fully seated in
annulus gear before proceeding.
(11) 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.
(12) Install planetary thrust bearing on sun gear
(Fig. 160). 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.
(13) Install assembled sun gear, spring plate and
thrust bearing (Fig. 161). Be sure sun gear and
thrust bearing are fully seated before proceeding.(14) 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.
(15) Align splines in hubs of planetary gear and
overrunning clutch with Alignment tool 6227-2 (Fig.
162). Insert tool through sun gear and into splines of
both hubs. Be sure alignment tool is fully seated
before proceeding.
Fig. 162 Alignment Tool Installation
1 - SPECIAL TOOL 6227-2
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
Fig. 159 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
Fig. 160 Planetary Thrust Bearing Installation
1 - SPRING PLATE
2 - PLANETARY THRUST BEARING
3 - SUN GEAR
Fig. 161 Sun Gear Installation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
21 - 408 AUTOMATIC TRANSMISSION - 48REDR
OVERDRIVE UNIT (Continued)

(16) Install direct clutch spring (Fig. 163). Be sure
spring is properly seated on spring plate.
NOTE: The direct clutch in a 48RE transmission
uses 23 single-sided clutch discs.
(17) Assemble and install direct clutch pack on
hub as follows:
(a) 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. 164).
(b) Install first clutch disc with external lugs fol-
lowed by a disc with internal spline teeth. Con-
tinue alternating internal and external discs until
all discs have been installed.
(c) Install pressure plate. This is last clutch pack
item to be installed. Be sure plate is installed with
shoulder side facing upward (Fig. 165).
Fig. 164 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. 165 Correct Position Of Direct Clutch
1 - DIRECT CLUTCH PRESSURE PLATE
2 - CLUTCH PACK
3 - BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
Fig. 163 Direct Clutch Spring Installation
1 - SPECIAL TOOL 6227-2
2 - DIRECT CLUTCH SPRING
3 - CLUTCH HUB
4 - PRESS PLATES
DRAUTOMATIC TRANSMISSION - 48RE 21 - 409
OVERDRIVE UNIT (Continued)

(18) Install clutch hub and clutch pack on direct
clutch spring (Fig. 166). Be sure hub is started on
sun gear splines before proceeding.
WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRES-
SOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 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.
(19) Position Compressor Tool 6227-1 on clutch
hub.
(20) Compress clutch hub and spring just enough
to place tension on hub and hold it in place.
(21) Slowly compress clutch hub and spring. Com-
press spring and hub only enough to expose ring
grooves for clutch pack snap-ring and clutch hub
retaining ring.
(22) Realign clutch pack on hub and seat clutch
discs and plates in clutch drum.(23) Install direct clutch pack snap-ring (Fig. 167).
Be very sure snap-ring is fully seated in clutch drum
ring groove.
(24) Install clutch hub retaining ring (Fig. 168). Be
very sure retaining ring is fully seated in sun gear
ring groove.
(25) Slowly release press ram, remove compressor
tools and remove geartrain assembly.
Fig. 166 Direct Clutch Pack And Clutch Hub
Installation
1 - CLUTCH HUB
2 - DIRECT CLUTCH PACK
3 - CLUTCH DRUM
Fig. 167 Direct Clutch Pack Snap-Ring Installation
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH PACK SNAP-RING
Fig. 168 Clutch Hub Retaining Ring Installation
1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RING
21 - 410 AUTOMATIC TRANSMISSION - 48REDR
OVERDRIVE UNIT (Continued)

GEAR CASE
(1) Position park pawl and spring in case and
install park pawl shaft. Verify that end of spring
with 90É bend is hooked to pawl and straight end of
spring is seated against case.
(2) Install pawl shaft retaining bolt. Tighten bolt
to 27 N´m (20 ft. lbs.) torque.
(3) Install park lock reaction plug. Note that plug
has locating pin at rear (Fig. 169). Be sure pin is
seated in hole in case before installing snap-ring.
(4) Install reaction plug snap-ring (Fig. 170). Com-
press snap-ring only enough for installation; do not
distort it.(5) Verify that tab ends of rear bearing locating
ring extend into access hole in gear case (Fig. 171).
(6) Support geartrain on Tool 6227-1 (Fig. 172). Be
sure tool is securely seated in clutch hub.
(7) Install overdrive gear case on geartrain (Fig.
172).
Fig. 169 Reaction Plug Locating Pin And Snap-Ring
1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 - LOCATING PIN
3 - PARK LOCK REACTION PLUG
Fig. 170 Reaction Plug And Snap-Ring Installation
1 - REACTION PLUG SNAP-RING
2 - SNAP-RING PLIERS
Fig. 171 Correct Rear Bearing Locating Ring
Position
1 - CASE ACCESS HOLE
2 - TAB ENDS OF LOCATING RING
Fig. 172 Overdrive Gear Case Installation
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
DRAUTOMATIC TRANSMISSION - 48RE 21 - 411
OVERDRIVE UNIT (Continued)

(8) Expand front bearing locating ring with snap-
ring pliers (Fig. 173). Then slide case downward until
locating ring locks in bearing groove and release
snap-ring.
(9) Install locating ring access cover and gasket in
overdrive unit case (Fig. 174).
OVERDRIVE CLUTCH
NOTE: The overdrive clutch in a 48RE transmission
uses 5 or 6 clutch discs depending on the applica-
tion.
(1) Install overdrive clutch reaction ring first.
Reaction ring is flat with notched ends (Fig. 175).
(2) For 5 disc overdrive clutch versions, install
wave spring on top of reaction ring (Fig. 176). Reac-
tion ring and wave ring both fit in same ring groove.
Use screwdriver to seat each ring securely in groove.Also ensure that the ends of the two rings are offset
from each other.
(3) Assemble overdrive clutch pack.
(4) Install overdrive clutch reaction plate first.
(5) Install first clutch disc followed by first clutch
plate. Then install remaining clutch discs and plates
in same order.
(6) Install clutch pack pressure plate.
(7) Install clutch pack wire-type retaining ring
(Fig. 177).
INTERMEDIATE SHAFT SPACER SELECTION
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
(2) Determine correct thickness intermediate shaft
spacer as follows:
(a) Insert Special Tool 6312 through sun gear,
planetary gear and into pilot bushing in output
shaft. Be sure tool bottoms against planetary
shoulder.
Fig. 173 Seating Locating Ring In Rear Bearing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 174 Locating Ring Access Cover And Gasket
Installation
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 175 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
Fig. 176 Overdrive Clutch Wave Spring Installation -
5 Disc Clutch Only
1 - WAVE SPRING
21 - 412 AUTOMATIC TRANSMISSION - 48REDR
OVERDRIVE UNIT (Continued)

(b) Position Gauge Tool 6311 across face of over-
drive case (Fig. 178). Then position Dial Caliper
C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Gauge Alignment Tool 6312. Lock scale in place.
Remove dial caliper tool and note distance mea-
sured (Fig. 178).
(d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig.
179).
(e) Remove Gauge Alignment Tool 6312.
OD THRUST PLATE SELECTION
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facingupward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
(2) Determine correct thickness overdrive piston
thrust plate as follows:
(a) Position Gauge Tool 6311 across face of over-
drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 180).
(b) Measure distance to clutch hub thrust bear-
ing seat at four points 90É apart. Then average
measurements by adding them and dividing by 4.
(c) Select and install required thrust plate from
information in thrust plate chart (Fig. 181).
(3) Leave Alignment Tool 6227-2 in place. Tool will
keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on trans-
mission.
(4) Transmission speed sensor can be installed at
this time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.
Fig. 177 Overdrive Clutch Pack Retaining Ring
Installation
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 178 Shaft End Play Measurement
1 - SPECIAL TOOL 6312
2 - SPECIAL TOOL 6311
3 - SPECIAL TOOL C-4962
Fig. 179 Intermediate Shaft End Play Spacer
Selection
Fig. 180 Overdrive Piston Thrust Plate Measurement
1 - SPECIAL TOOL 6311
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
3 - SPECIAL TOOL C-4962
DRAUTOMATIC TRANSMISSION - 48RE 21 - 413
OVERDRIVE UNIT (Continued)

OVERDRIVE PISTON
(1) Install new seals on overdrive piston.
(2) Stand transmission case upright on bellhous-
ing.
(3) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(4) Position Seal Guide 8114-3 on inner edge of
overdrive piston retainer.
(5) Install overdrive piston in overdrive piston
retainer by:
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
ATF+4.
(c) Install piston over Seal Guide 8114-3 and
inside Guide Ring 8114-1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
(6) Install intermediate shaft spacer on intermedi-
ate shaft.
(7) Install overdrive piston thrust plate on over-
drive piston.
(8) Install overdrive piston thrust bearing on over-
drive piston.
(9) Install transmission speed sensor and o-ring
seal in overdrive case.
INSTALLATION
(1) Be sure overdrive unit Alignment Tool 6227-2
is fully seated before moving unit. If tool is not
seated and gear splines rotate out of alignment, over-
drive unit will have to be disassembled in order to
realign splines.
(2) If overdrive piston retainer was not removed
during service and original case gasket is no longer
reusable, prepare new gasket by trimming it.(3) Cut out old case gasket around piston retainer
with razor knife (Fig. 182).
(4) Use old gasket as template and trim new gas-
ket to fit.
(5) Position new gasket over piston retainer and
on transmission case. Use petroleum jelly to hold
gasket in place if necessary. Do not use any type of
sealer to secure gasket. Use petroleum jelly only.
(6) Install selective spacer on intermediate shaft, if
removed. Spacer goes in groove just rearward of
shaft rear splines (Fig. 183).
(7) Install thrust bearing in overdrive unit sliding
hub. Use petroleum jelly to hold bearing in position.
CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Align-
Fig. 181 Overdrive Piston Thrust Plate Selection
Fig. 182 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 183 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
3 - INTERMEDIATE SHAFT
21 - 414 AUTOMATIC TRANSMISSION - 48REDR
OVERDRIVE UNIT (Continued)