Transmission DODGE RAM 2003 Service Repair Manual

between the rollers and cam. This increased clear-
ance between the rollers and cam results in a free-
wheeling condition. When the inner race attempts to
rotate counterclockwise, the action causes the rollers
to roll in the same direction as the race, aided by the
pushing of the springs. As the rollers try to move in
the same direction as the inner race, they are
wedged between the inner and outer races due to the
design of the cam. In this condition, the clutch is
locked and acts as one unit.
DISASSEMBLY
(1) Remove the overdrive piston (Fig. 201).
(2) Remove the overdrive piston retainer bolts.
(3) Remove overdrive piston retainer.
(4) Remove case gasket.
(5) Tap old cam out of case with pin punch. Insert
punch through bolt holes at rear of case (Fig. 202).
Alternate position of punch to avoid cocking cam dur-
ing removal.
(6) Clean clutch cam bore and case. Be sure to
remove all chips/shavings generated during cam
removal.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
low-reverse drum, and overdrive piston retainer in
solvent. Dry them with compressed air after clean-
ing.
INSPECTION
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring
assembly if any rollers or springs are worn or dam-
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse drum if the clutch race,
roller surface or inside diameter is scored, worn or
damaged.Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Examine the overdrive piston retainer carefully for
wear, cracks, scoring or other damage. Be sure the
retainer hub is a snug fit in the case and drum.
Replace the retainer if worn or damaged.
Fig. 201 Overdrive Piston Removal
1 - OVERDRIVE CLUTCH PISTON
2 - INTERMEDIATE SHAFT
3 - SELECTIVE SPACER
4 - PISTON RETAINER
Fig. 202 Overrunning Clutch Cam
1 - PIN PUNCH
2 - REAR SUPPORT BOLT HOLES
21 - 238 AUTOMATIC TRANSMISSION - 46REDR
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

ASSEMBLY
(1) Temporarily install overdrive piston retainer in
case. Use 3-4 bolts to secure retainer.
(2) Align and start new clutch cam in the trans-
mission case. Be sure serrations on cam and in case
are aligned (Fig. 203). Then tap cam into case just
enough to hold it in place.
(3) Verify that cam is correctly positioned before
proceeding any further. Narrow ends of cam ramps
should be to left when cam is viewed from front end
of case (Fig. 203).
(4) Insert Adapter Tool SP-5124 into piston
retainer (Fig. 204).
(5) Assemble Puller Bolt SP-3701 and Press Plate
SP-3583-A (Fig. 205).
(6) Install assembled puller plate and bolt (Fig.
206). Insert bolt through cam, case and adapter tool.
Be sure plate is seated squarely on cam.
Fig. 206 Positioning Puller Plate On Clutch Cam
1 - SPECIAL TOOL SP-3701
2 - BE SURE PLATE SP-3583-A IS SEATED SQUARELY ON CAM
Fig. 203 Positioning Replacement Clutch Cam In
Case
1 - ALIGN SERRATIONS ON CAM AND IN CASE
2 - CLUTCH CAM
Fig. 204 Positioning Adapter Tool In Overdrive
Piston Retainer
1 - PISTON RETAINER
2 - SPECIAL TOOL SP-5124
Fig. 205 Assembling Clutch Cam Puller Bolt And
Press Plate
1 - PULLER BOLT SP-3701
2 - PRESS PLATE SP-3583-A
DRAUTOMATIC TRANSMISSION - 46RE 21 - 239
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

(7) Hold puller plate and bolt in place and install
puller nut SP-3701 on puller bolt (Fig. 207).
(8) Tighten puller nut to press clutch cam into
case (Fig. 207). Be sure cam is pressed into case
evenly and does not become cocked.
(9) Remove clutch cam installer tools.
(10) Stake case in 14 places around clutch cam to
help secure cam in case. Use blunt punch or chisel to
stake case.
(11) Remove piston retainer from case. Cover
retainer with plastic sheeting, or paper to keep it
dust free.
(12) Clean case and cam thoroughly. Be sure any
chips/shavings generated during cam installation are
removed from case.
(13) Install new gasket at rear of transmission
case. Use petroleum jelly to hold gasket in place. Be
sure to align governor feed holes in gasket with feed
passages in case (Fig. 208). Also install gasket before
overdrive piston retainer. Center hole in gasket is
smaller than retainer and cannot be installed over
retainer.
(14) Position overdrive piston retainer on trans-
mission case and align bolt holes in retainer, gasket
and case (Fig. 209). Then install and tighten retainer
bolts to 17 N´m (13 ft. lbs.) torque.
(15) Install new seals on overdrive piston.
(16) Stand transmission case upright on bellhous-
ing.(17) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(18) Position Seal Guide 8114-3 on inner edge of
overdrive piston retainer.
Fig. 207 Pressing Overrunning Clutch Cam Into
Case
1 - SPECIAL TOOL SP-3583-A
2 - TIGHTEN NUT TO DRAW CAM INTO CASE (NUT IS PART OF
BOLT SP-3701)
3 - SPECIAL TOOL SP-5124
4 - SPECIAL TOOL SP-3701
Fig. 208 Installing/Aligning Case Gasket
1 - CASE GASKET
2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
Fig. 209 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
21 - 240 AUTOMATIC TRANSMISSION - 46REDR
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

(19) Install overdrive piston in overdrive piston
retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(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.
PISTONS
DESCRIPTION
There are several sizes and types of pistons used in
an automatic transmission. Some pistons are used to
apply clutches, while others are used to apply bands.
They all have in common the fact that they are
round or circular in shape, located within a smooth
walled cylinder, which is closed at one end and con-
verts fluid pressure into mechanical movement. The
fluid pressure exerted on the piston is contained
within the system through the use of piston rings or
seals.
OPERATION
The principal which makes this operation possible
is known as Pascal's Law. Pascal's Law can be stated
as: ªPressure on a confined fluid is transmitted
equally in all directions and acts with equal force on
equal areas.º
PRESSURE
Pressure (Fig. 210) is nothing more than force
(lbs.) divided by area (in or ft.), or force per unit
area. Given a 100 lb. block and an area of 100 sq. in.
on the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.
PRESSURE ON A CONFINED FLUID
Pressure is exerted on a confined fluid (Fig. 211) by
applying a force to some given area in contact with
the fluid. A good example of this is a cylinder filled
with fluid and equipped with a piston that is closely
fitted to the cylinder wall. If a force is applied to the
piston, pressure will be developed in the fluid. Of
course, no pressure will be created if the fluid is not
confined. It will simply ªleakº past the piston. There
must be a resistance to flow in order to create pres-
sure. Piston sealing is extremely important in
hydraulic operation. Several kinds of seals are usedto accomplish this within a transmission. These
include but are not limited to O-rings, D-rings, lip
seals, sealing rings, or extremely close tolerances
between the piston and the cylinder wall. The force
exerted is downward (gravity), however, the principle
remains the same no matter which direction is taken.
The pressure created in the fluid is equal to the force
applied, divided by the piston area. If the force is 100
lbs., and the piston area is 10 sq. in., then the pres-
sure created equals 10 PSI. Another interpretation of
Pascal's Law is that regardless of container shape or
size, the pressure will be maintained throughout, as
long as the fluid is confined. In other words, the
pressure in the fluid is the same everywhere within
the container.
Fig. 210 Force and Pressure Relationship
Fig. 211 Pressure on a Confined Fluid
DRAUTOMATIC TRANSMISSION - 46RE 21 - 241
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

FORCE MULTIPLICATION
Using the 10 PSI example used in the illustration
(Fig. 212), a force of 1000 lbs. can be moved with a
force of only 100 lbs. The secret of force multiplica-
tion in hydraulic systems is the total fluid contact
area employed. The illustration, (Fig. 212), shows an
area that is ten times larger than the original area.
The pressure created with the smaller 100 lb. input
is 10 PSI. The concept ªpressure is the same every-
whereº means that the pressure underneath the
larger piston is also 10 PSI. Pressure is equal to the
force applied divided by the contact area. Therefore,
by means of simple algebra, the output force may be
found. This concept is extremely important, as it is
also used in the design and operation of all shift
valves and limiting valves in the valve body, as well
as the pistons, of the transmission, which activate
the clutches and bands. It is nothing more than
using a difference of area to create a difference in
pressure to move an object.
PISTON TRAVEL
The relationship between hydraulic lever and a
mechanical lever is the same. With a mechanical
lever it's a weight-to-distance output rather than a
pressure-to-area output. Using the same forces and
areas as in the previous example, the smaller piston
(Fig. 213) has to move ten times the distance
required to move the larger piston one inch. There-
fore, for every inch the larger piston moves, the
smaller piston moves ten inches. This principle is
true in other instances also. A common garage floor
jack is a good example. To raise a car weighing 2000
lbs., an effort of only 100 lbs. may be required. For
every inch the car moves upward, the input piston at
the jack handle must move 20 inches downward.
PLANETARY GEARTRAIN/
OUTPUT SHAFT
DESCRIPTION
The planetary gearsets (Fig. 214) are designated as
the front, rear, and overdrive planetary gear assem-
blies and located in such order. A simple planetary
gearset consists of three main members:
Fig. 212 Force Multiplication
Fig. 213 Piston Travel
Fig. 214 Planetary Gearset
1 - ANNULUS GEAR
2 - SUN GEAR
3 - PLANET CARRIER
4 - PLANET PINIONS (4)
21 - 242 AUTOMATIC TRANSMISSION - 46REDR
PISTONS (Continued)

²The sun gear which is at the center of the sys-
tem.
²The planet carrier with planet pinion gears
which are free to rotate on their own shafts and are
in mesh with the sun gear.
²The annulus gear, which rotates around and is
in mesh with the planet pinion gears.
NOTE: The number of pinion gears does not affect
the gear ratio, only the duty rating.
OPERATION
With any given planetary gearset, several condi-
tions must be met for power to be able to flow:
²One member must be held.
²Another member must be driven or used as an
input.
²The third member may be used as an output for
power flow.
²For direct drive to occur, two gear members in
the front planetary gearset must be driven.
NOTE: Gear ratios are dependent on the number of
teeth on the annulus and sun gears.
DISASSEMBLY
(1) Remove planetary snap-ring from intermediate
shaft (Fig. 215). Discard snap-ring as it is not reus-
able.
(2) Remove front planetary gear and front annulus
gear as assembly (Fig. 216).
(3) Remove front planetary gear and thrust
washer from front annulus gear (Fig. 217). Note
thrust washer position for assembly reference.
Fig. 215 Removing Planetary Snap-Ring
1 - PLANETARY SNAP-RING
Fig. 216 Removing Front Planetary And Annulus
Gears
1 - DRIVING SHELL
2 - FRONT ANNULUS GEAR
3 - FRONT PLANETARY GEAR
Fig. 217 Disassembling Front Planetary And
Annulus Gears
1 - FRONT PLANETARY GEAR
2 - TABBED THRUST WASHER
3 - FRONT ANNULUS GEAR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 243
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(4) Remove tabbed thrust washer from driving
shell (Fig. 218). Note washer position for assembly
reference.
(5) Remove sun gear and driving shell as assembly
(Fig. 219).
(6) Remove tabbed thrust washer from rear plane-
tary gear (Fig. 220). Note washer position on gear for
assembly reference.
(7) Remove rear planetary gear and rear annulus
gear from intermediate shaft (Fig. 221).
(8) Remove thrust plate from rear annulus gear
(Fig. 222).
Fig. 218 Driving Shell Thrust Washer Removal
1 - DRIVING SHELL
2 - TABBED THRUST WASHER
3 - SUN GEAR
Fig. 219 Sun Gear And Driving Shell Removal
1 - INTERMEDIATE SHAFT
2 - DRIVING SHELL
3 - SUN GEAR
Fig. 220 Rear Planetary Thrust Washer Removal
1 - SUN GEAR
2 - REAR PLANETARY THRUST WASHER
3 - DRIVING SHELL
Fig. 221 Rear Planetary And Annulus Gear Removal
1 - INTERMEDIATE SHAFT
2 - REAR ANNULUS GEAR
3 - REAR PLANETARY GEAR
Fig. 222 Rear Annulus Thrust Plate Removal
1 - REAR ANNULUS GEAR
2 - THRUST PLATE
21 - 244 AUTOMATIC TRANSMISSION - 46REDR
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

INSPECTION
Inspect the planetary gear sets and annulus gears.
The planetary pinions, shafts, washers, and retaining
pins are serviceable. However, if a pinion carrier is
damaged, the entire planetary gear set must be
replaced as an assembly.
Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash-
ers if cracked, scored or worn.
Inspect the machined surfaces of the intermediate
shaft. Be sure the oil passages are open and clear.
Replace the shaft if scored, pitted, or damaged.
Inspect the sun gear and driving shell. If either
component is worn or damaged, remove the sun gear
rear retaining ring and separate the sun gear and
thrust plate from the driving shell. Then replace the
necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as
an assembly if the bushings are scored or worn. The
sun gear bushings are not serviceable. Replace the
thrust plate if worn, or severely scored. Replace the
driving shell if distorted, cracked, or damaged in any
way.
Replace all snap-rings during geartrain assembly.
Reusing snap-rings is not recommended.
ASSEMBLY
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly to lubricate intermediate shaft bushing surfaces,
thrust washers and thrust plates and to hold these
parts in place during assembly.
(2) Install front snap-ring on sun gear and install
gear in driving shell. Then install thrust plate oversun gear and against rear side of driving shell (Fig.
223). Install rear snap-ring to secure sun gear and
thrust plate in driving shell.
(3) Install rear annulus gear on intermediate shaft
(Fig. 224).
(4) Install thrust plate in annulus gear (Fig. 225).
Be sure plate is seated on shaft splines and against
gear.
Fig. 223 Sun Gear Installation
1 - DRIVING SHELL
2 - SUN GEAR
3 - THRUST PLATE
4 - SUN GEAR REAR RETAINING RING
Fig. 224 Installing Rear Annulus Gear On
Intermediate Shaft
1 - REAR ANNULUS GEAR
2 - OUTPUT SHAFT
Fig. 225 Installing Rear Annulus Thrust Plate
1 - REAR ANNULUS GEAR
2 - THRUST PLATE
DRAUTOMATIC TRANSMISSION - 46RE 21 - 245
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(5) Install rear planetary gear in rear annulus
gear (Fig. 226). Be sure planetary carrier is seated
against annulus gear.
(6) Install tabbed thrust washer on front face of
rear planetary gear (Fig. 227). Seat washer tabs in
matching slots in face of gear carrier. Use extra
petroleum jelly to hold washer in place if desired.
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
(8) Install sun gear and driving shell on interme-
diate shaft (Fig. 228). Seat shell against rear plane-
tary gear. Verify that thrust washer on planetary
gear was not displaced during installation.
(9) Install tabbed thrust washer in driving shell
(Fig. 229), be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
washer in place if desired.
Fig. 226 Installing Rear Planetary Gear
1 - REAR ANNULUS GEAR
2 - REAR PLANETARY GEAR
Fig. 227 Installing Rear Planetary Thrust Washer
1 - REAR PLANETARY GEAR
2 - TABBED THRUST WASHER
Fig. 228 Installing Sun Gear And Driving Shell
1 - OUTPUT SHAFT
2 - DRIVING SHELL
3 - REAR PLANETARY GEAR
4 - OUTPUT SHAFT
5 - SUN GEAR
Fig. 229 Installing Driving Shell Thrust Washer
1 - TAB SLOTS (3)
2 - DRIVING SHELL
3 - TABBED THRUST WASHER
21 - 246 AUTOMATIC TRANSMISSION - 46REDR
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(10) Install tabbed thrust washer on front plane-
tary gear (Fig. 230). Seat washer tabs in matching
slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
(11) Install front annulus gear over and onto front
planetary gear (Fig. 231). Be sure gears are fully
meshed and seated.
(12) Install front planetary and annulus gear
assembly (Fig. 232). Hold gears together and slide
them onto shaft. Be sure planetary pinions are
seated on sun gear and that planetary carrier is
seated on intermediate shaft.
(13) Place geartrain in upright position. Rotate
gears to be sure all components are seated and prop-
erly assembled. Snap-ring groove at forward end of
intermediate shaft will be completely exposed when
components are assembled correctly.
Fig. 231 Assembling Front Planetary And Annulus
Gears
1 - FRONT ANNULUS GEAR
2 - FRONT PLANETARY GEAR
Fig. 232 Installing Front Planetary And Annulus
Gear Assembly
1 - DRIVING SHELL
2 - ASSEMBLED FRONT PLANETARY AND ANNULUS GEARS
Fig. 230 Installing Thrust Washer On Front
Planetary Gear
1 - TABBED THRUST WASHER
2 - FRONT PLANETARY GEAR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 247
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)