clutch DODGE RAM 2003 Service Repair Manual

(23) Remove the number 1 bearing from the input
clutch assembly (Fig. 23).
(24) Remove the input clutch assembly from the
transmission case (Fig. 23).
(25) Remove the number 5 bearing and selective
thrust plate from the input clutch assembly (Fig. 23),
or the 4C clutch retainer/bulkhead.
(26) Remove the 4C clutch retainer/bulkhead
tapered snap-ring from the transmission case (Fig.
24).
(27) Remove the 4C clutch retainer/bulkhead from
the transmission case (Fig. 24).
(28) Remove the front 2C clutch pack snap-ring
from the transmission case (Fig. 25).
(29) Remove the 2C clutch pack from the transmis-
sion case (Fig. 25).
(30) Remove the rear selective plate and number 6
bearing from the reaction annulus (Fig. 26).
(31) Remove the reaction annulus from the reac-
tion planetary carrier (Fig. 26).
(32) Remove the number 7 bearing (Fig. 26).
(33) Remove the reaction sun gear (Fig. 26).
(34) Remove the number 8 bearing from the reac-
tion planetary carrier (Fig. 26).
(35) Remove the reaction planetary carrier (Fig.
26). Note that this planetary gear set has three pin-
ion gears.
(36) Remove the number 9 bearing from the
reverse planetary gear set (Fig. 26).
(37) Remove the snap-ring holding the park sprag
gear onto the output shaft (Fig. 27).
(38) Remove the park sprag gear from the output
shaft (Fig. 28).
Fig. 23 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 24 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 25 Remove 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(39) Remove the input/reverse planetary assembly
(Fig. 29).
(40) Remove the number 12 bearing from the
input/reverse planetary assembly (Fig. 29).
(41) Remove the snap-ring holding the low/reverse
clutch retainer into the transmission case (Fig. 30).
(42) Remove the low/reverse clutch retainer from
the transmission case (Fig. 30).
(43) Remove the park pawl rod and e-clip (Fig. 31).
(44) Remove the park pawl rod guide snap-ring
(Fig. 31).
(45) Remove the park pawl rod guide (Fig. 31).(46) Remove the park pawl pivot shaft, park pawl,
and spring (Fig. 31).
(47) Remove the manual selector shaft (Fig. 31).
(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
CLEANING
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with MopartATF +4,
Automatic Transmission Fluid, during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-Glyde to prelubricate seals, O-rings, and thrust
Fig. 29 Remove Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
Fig. 30 Remove Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 31 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
21 - 502 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(9) Install a new dipstick tube seal using Seal
Installer 8254 (Fig. 34).
NOTE: Before final assembly of transmission cen-
terline, the 2C/4C clutch components should be
installed into position and measured as follows:
(10) Install the 2C reaction plate into the trans-
mission case (Fig. 35). The reaction plate is direc-
tional. The plate must be installed with the flat side
toward the front of the transmission.
(11) Install the 2C clutch pack into the transmis-
sion case (Fig. 35).
(12) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 35).
(13) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area.
(14) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case. Make sure that
the open ends of the snap-ring are located in the case
opening toward the valve body area.
(15) Using a feeler gauge through the opening in
the rear of the transmission case, measure the 2C
clutch pack clearance between the 2C reaction plate
and the transmission case at four different points.
The average of these measurements is the 2C clutch
pack clearance. The correct clutch clearance is 0.455-
1.335 mm (0.018-0.053 in.). The reaction plate is not
selective. If the clutch pack clearance is not within
specification, the reaction plate, all the friction discs,
and steels must be replaced.
(16) Remove the 4C retainer/bulkhead and all of
the 2C clutch components from the transmission
case.(17) Install the low/reverse clutch assembly (Fig.
36). Make sure that the oil feed hole points toward
the valve body area and that the bleed orifice is
aligned with the notch in the rear of the transmis-
sion case.
(18) Install the snap-ring to hold the low/reverse
clutch retainer into the transmission case (Fig. 36).
The snap-ring is tapered and must be installed with
the tapered side forward. Once installed, verify that
the snap-ring is fully seated in the snap-ring groove.
(19) Air check the low/reverse clutch and verify
correct overrunning clutch operation.
Fig. 34 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 35 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 36 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
21 - 504 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(20) Install the number 12 bearing over the output
shaft and against the rear planetary gear set. The
flat side of the bearing goes toward the planetary
gearset and the raised tabs on the inner race should
face the rear of the transmission.
(21) Install the reverse/input planetary assembly
through the low/reverse clutch assembly (Fig. 37).
(22) Install the park sprag onto the output shaft
(Fig. 38).
(23) Install the snap-ring to hold the park sprag
onto the output shaft (Fig. 39).(24) Install the 2C reaction plate into the trans-
mission case (Fig. 40). The reaction plate is direc-
tional. The plate must be installed with the flat side
toward the front of the transmission.
(25) Install the 2C clutch pack into the transmis-
sion case (Fig. 40).
(26) Install the number 8 bearing inside the reac-
tion carrier with the outer race against the reaction
planetary carrier.
Fig. 37 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
Fig. 38 Install Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 39 Install Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 40 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 505
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(27) Install the reaction planetary gear set and the
number 9 bearing, with the inner race against the
reaction planetary carrier, into the transmission case
(Fig. 41).
(28) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 40).
(29) Install the reaction sun gear into the reaction
planetary gear set.Make surethe small shoulder is
facing the front of the transmission (Fig. 41).
(30) Install the number 7 bearing onto the reaction
sun gear with the inner race against the sun gear
(Fig. 41).
(31) Install the output shaft selective thrust plate
onto the reaction annulus with the oil grooves facing
the annulus gear and the tabs and notches aligned as
shown in (Fig. 42).
(32)
Install the number 6 bearing against the output
shaft selective thrust plate with the flat side against the
thrust plate (Fig. 41) and the raised tabs on the inner
race facing the front of the transmission.
(33) Install the reaction annulus into the reaction
planetary gear set (Fig. 41).
Fig. 41 Install Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
Fig. 42 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
21 - 506 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(34) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the
reaction annulus during the installation of the 4C
retainer/bulkhead to ease installation.
(35) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case (Fig. 43) with
the taper toward the front of the case. Make sure
that the open ends of the snap-ring are located in the
case opening toward the valve body area.
(36) Air check the 2C and 4C clutch operation.
(37) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator
C-3339, measure and record the output shaft end-
play (Fig. 44). The correct output shaft end-play is
0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary.
Install the chosen output shaft selective thrust plate
and re-measure end-play to verify selection.
(38) Apply a bead of RTV silicone and install the
extension/adapter housing onto the transmission
case.
(39) Install and torque the bolts to hold the exten-
sion/adapter housing onto the transmission case. The
correct torque is 54 N´m (40 ft.lbs.).
(40) Install the number 5 bearing and selective
thrust plate onto the 4C retainer/bulkhead (Fig. 45).
Be sure that the outer race of the bearing is against
the thrust plate.(41) Install the input clutch assembly into the
transmission case (Fig. 45). Make sure that the input
clutch assembly is fully installed by performing a
visual inspection through the input speed sensor
hole. If the tone wheel teeth on the input clutch
assembly are centered in the hole, the assembly is
fully installed.
(42) Install the number 1 bearing with the outer
race up in the pocket of the input clutch assembly
(Fig. 45).
Fig. 43 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 44 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 45 Install Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 507
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(43) Install the oil pump into the transmission
case (Fig. 46).
(44) Install the bolts to hold the oil pump into the
transmission case. Tighten the oil pump bolts to 28
N´m (250 in.lbs.).
(45) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 47). The correct end-
play is 0.46-0.89 mm (0.018-0.035 in.). Adjust as nec-
essary. Install the chosen thrust plate on the number
5 bearing and re-measure end-play to verify selec-
tion.
NOTE: When measuring the input shaft end-play,
two(stops(will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first(stop(felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(46) Install the transmission front cover into the
transmission case (Fig. 48).
(47) Install the outer snap-ring to hold the trans-
mission front cover into the transmission case (Fig.
48).
(48) Partially install the inner transmission front
cover snap-ring onto the oil pump (Fig. 48).
Fig. 46 Install Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 47 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 48 Install the Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
21 - 508 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(21) Connect wires to solenoid and pressure switch
assembly (Fig. 55) connector, input (Fig. 56) and out-
put (Fig. 57) speed sensors, and line pressure sensor
(Fig. 58). Be sure transmission harnesses are prop-
erly routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.(22) Install torque converter-to-driveplate bolts.
Tighten bolts to 31 N´m (270 in. lbs.).
(23) Install starter motor and cooler line bracket.
(24) Connect cooler lines to transmission.
(25) Install transmission fill tube.
(26) Install exhaust components, if necessary.
Fig. 55 Connect Transmission Solenoid
1 - TRANSMISSION
2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
Fig. 56 Connect Input Speed Sensor
1 - TRANSMISSION
2 - INPUT SPEED SENSOR
Fig. 57 Connect Output Speed Sensor
1 - TRANSMISSION
2 - OUTPUT SPEED SENSOR
Fig. 58 Connect Line Pressure Sensor
1 - TRANSMISSION
2 - LINE PRESSURE SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 511
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Output Shaft End Play 0.22-0.55
mm0.009-0.021
in.
Input Shaft End Play 0.46-0.89
mm0.018-0.035
in.
2C Clutch Pack
Clearance0.455-1.335
mm0.018-0.053
in.
4C Clutch Pack
Clearance0.770-1.390
mm0.030-0.055
in.
L/R Clutch Pack
Clearance1.00-1.74
mm0.039-0.069
in.
OD Clutch Pack
Clearance1.103-1.856
mm0.043-0.073
in.
Component Metric Inch
UD Clutch Pack
Clearance0.84-1.54
mm0.033-0.061
in.
Reverse Clutch Pack
Clearance0.81-1.24
mm0.032-0.049
in.
Recommended fluid MoparTAT F + 4
GEAR RATIOS
1ST 3.00:1
2ND 1.67:1
2ND Prime 1.50:1
3RD 1.0:1
4TH 0.75:1
5TH 0.67:1
REVERSE 3.00:1
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fitting, cooler line at trans 17.5 - 155
Bolt, torque convertor 31 23 -
Bolt/nut, crossmember 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Bolt, oil pan 11.8 - 105
Screw, primary fluid filter 4.5 - 40
Bolt, oil pump 28.2 - 250
Bolt, oil pump body to cover 4.5 - 40
Screw, plate to oil pump body 4.5 - 40
Bolt, valve body to case 11.8 - 105
Plug, pressure test port 5.1 - 45
Bolt, reaction shaft support 11.8 - 105
Screw, valve body to transfer plate 5.6 - 50
Screw, solenoid module to transfer plate 5.7 - 50
Screw, accumulator cover 4.5 - 40
Screw, detent spring 4.5 - 40
Bolt, input speed sensor 11.8 - 105
Bolt, output speed sensor 11.8 - 105
Bolt, line pressure sensor 11.8 - 105
Bolt, extension housing 54 40 -
Valve, cooler return filter bypass 4.5 - 40
Screw, manual valve cam retaining 4.5 - 40
Bolt, manual lever 28.2 - 250
21 - 534 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

Installer, Seal - 8253
Installer, Seal - 8254
Installer, Snap-ring - 8255
Stand, Support - 8257
Adapter, Pressure Tap - 8258-A
Adapter, Line Pressure - 8259
Fixture, Input Clutch Pressure - 8260
Plate, Alignment - 8261
21 - 536 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)