automatic transmission DODGE RAM 2003 Service Repair Manual

HYDRAULIC FLOW IN FIFTH EMCC
21 - 530 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

HYDRAULIC FLOW IN MANUAL LOW OR AUTOSTICK 1ST
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 531
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

HYDRAULIC FLOW IN MANUAL SECOND
21 - 532 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

HYDRAULIC FLOW IN MANUAL SECOND (FAILSAFE)
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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
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

SPECIAL TOOLS
RFE TRANSMISSION
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Installer, Seal - C-3860-A
Compressor, Spring - 8249
Compressor, Spring - 8250
Compressor, Spring - 8251
Installer, Piston - 8252
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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
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

Wrench, Filter - 8321
Installer, Piston - 8504
End Play Set - 8266
Compressor, Spring - 8285
Installer, Bearing - 8320
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

4C RETAINER/BULKHEAD
DISASSEMBLY
(1) Remove the 2C piston belleville spring snap-
ring from the 4C retainer /bulkhead (Fig. 60).
(2) Remove the 2C piston Belleville spring from
the retainer/bulkhead (Fig. 60).
(3) Remove the 2C piston from the retainer/bulk-
head. Use 20 psi of air pressure to remove the piston
if necessary.
(4) Remove the 4C clutch snap-ring from the
retainer/bulkhead (Fig. 60).
(5) Remove the 4C clutch pack from the retainer/
bulkhead (Fig. 60).
(6) Using Spring Compressor 8250 and a suitable
shop press, compress the 4C piston return spring and
remove the snap-ring (Fig. 60).(7) Remove the 4C piston return spring and piston
from the retainer/bulkhead (Fig. 60). Use 20 psi of
air pressure to remove the piston if necessary.ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install new seals on the 2C and 4C pistons
(Fig. 60).
(3) Lubricate all seals with MopartATF +4 prior
to installation.
(4) Install the 4C piston into the 4C retainer/bulk-
head (Fig. 60).
(5) Position the 4C piston return spring onto the
4C piston.
Fig. 60 4C Retainer/Bulkhead Components
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
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(6) Using Spring Compressor 8250 and a suitable
shop press, compress the 4C piston return spring and
install the snap-ring (Fig. 61).
(7) Assemble and install the 4C clutch pack into
the retainer/bulkhead (Fig. 60) with the steel separa-
tor plate against the piston.
(8) Install the 4C reaction plate and snap-ring into
the retainer/bulkhead (Fig. 60). The 4C reaction plate
is non-directional.
(9) Measure the 4C clutch clearance. The correct
clutch clearance is 0.77-1.39 mm (0.030-0.055 in.).
The snap-ring is selectable. Install the chosen snap-
ring and re-measure to verify the selection.
(10) Install the 2C piston into the retainer/bulk-
head (Fig. 60).
(11) Position the 2C Belleville spring onto the 2C
piston.
(12) Position the 2C Belleville spring snap-ring
onto the 2C Belleville spring (Fig. 60).
(13) Using Spring Compressor 8249 and a suitable
shop press (Fig. 62), compress the belleville spring
until the snap-ring is engaged with the snap-ring
groove in the retainer/bulkhead.
ADAPTER HOUSING SEAL
REMOVAL
(1) Remove the transfer case from the transmis-
sion.
(2) Using a screw mounted on a slide hammer,
remove the adapter housing seal.
INSTALLATION
(1) Clean the adapter seal bore in the adapter
housing of any residue or particles remaining from
the original seal.
(2) Install new oil seal in the adapter housing
using Seal Installer C-3860-A (Fig. 63). A properly
installed seal is flush to the face of the seal bore.
(3) Install the transfer case onto the transmission.
Fig. 61 Compress 4C Piston Return Spring Using
Tool 8250
1 - PRESS
2 - TOOL 8250
Fig. 62 Compress 2C Belleville Spring Using Tool
8249
1 - PRESS
2 - TOOL 8249
Fig. 63 Adapter Housing Seal Installation
1 - TOOL C-3860-A
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4C RETAINER/BULKHEAD (Continued)