brake DODGE RAM SRT-10 2006 Service Repair Manual

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AUTOMATIC TRANSMISSION 42RLE - SERVICE
INFORMATION
DESCRIPTION ............................... 391
OPERATION ................................. 393
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION ............... 398
ROAD TEST ............................... 399
HYDRAULIC PRESSURE TESTS............ 400
CLUTCH AIR PRESSURE TESTS........... 402
FLUID LEAKAGE.......................... 403
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR .......................... 404
REMOVAL ................................... 404
DISASSEMBLY .............................. 406
ASSEMBLY .................................. 428
INSTALLATION .............................. 451
SCHEMATICS AND DIAGRAMS
42RLE - WITHOUT VARIABLE LINE
PRESSURE............................... 455
42RLE - WITH VARIABLE LINE PRESSURE . . 469
SPECIFICATIONS
42RLE AUTOMATIC TRANSMISSION ........ 479
SPECIAL TOOLS
42RLE AUTOMATIC TRANSMISSION ........ 481
ACCUMULATOR
DESCRIPTION ............................... 485
OPERATION ................................. 486
SEAL-ADAPTER HOUSING
REMOVAL ................................... 487
INSTALLATION .............................. 487
BEARINGS
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURES.... 488
MECHANISM-BRAKE TRANSMISSION SHIFT
INTERLOCK
DESCRIPTION ............................... 489
OPERATION ................................. 489
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK ......... 489
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK ......................... 489
CLUTCHES-DRIVING
DESCRIPTION ............................... 491
OPERATION ................................. 491
SEAL-EXTENSION HOUSING
REMOVAL ................................... 492
INSTALLATION .............................. 492
FLUID AND FILTER
DIAGNOSIS AND TESTING
CAUSES OF BURNT FLUID ................. 493EFFECTS OF INCORRECT FLUID LEVEL . . . . 493
FLUID CONTAMINATION ................... 493
STANDARD PROCEDURE
FLUID LEVEL CHECK...................... 493
FLUID/FILTER SERVICE .................... 494
TRANSMISSION FILL ...................... 495
CABLE-GEARSHIFT
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE .................................... 496
REMOVAL ................................... 496
INSTALLATION .............................. 497
ADJUSTMENTS - GEARSHIFT CABLE ......... 498
CLUTCHES-HOLDING
DESCRIPTION ............................... 499
OPERATION ................................. 499
ASSEMBLY-INPUT CLUTCH
DISASSEMBLY .............................. 500
ASSEMBLY .................................. 509
SENSOR-INPUT SPEED
DESCRIPTION ............................... 523
OPERATION ................................. 523
REMOVAL ................................... 523
INSTALLATION .............................. 524
SENSOR-VARIABLE LINE PRESSURE
DESCRIPTION ............................... 525
OPERATION ................................. 525
REMOVAL ................................... 525
INSTALLATION .............................. 526
PUMP-OIL
DESCRIPTION ............................... 527
OPERATION ................................. 527
DISASSEMBLY .............................. 527
ASSEMBLY .................................. 529
SENSOR-OUTPUT SPEED
DESCRIPTION ............................... 530
OPERATION ................................. 530
REMOVAL ................................... 530
INSTALLATION .............................. 531
GEARTRAIN-PLANETARY
DESCRIPTION ............................... 532
OPERATION ................................. 532
SEAL-OIL PUMP
REMOVAL ................................... 533
INSTALLATION .............................. 533
SOLENOID-PRESSURE CONTROL
DESCRIPTION ............................... 534
OPERATION ................................. 534
REMOVAL ................................... 534
INSTALLATION .............................. 535

TEST THREE - SELECTOR IN DRIVE (OD OFF - Third and Second Gear)
NOTE: This test checks the overdrive clutch hydraulic circuit as well as the shift schedule.
1. Attach gauge to the overdrive clutch tap.
2. Move selector lever to the DRIVE position.
3. Allow vehicle wheels to turn and increase throttle opening to achieve anindicated vehicle speed of 20 mph.
4. Overdrive clutch pressure should read 74 to 95 psi.
5. Move selector lever to the DRIVE position and increase indicated vehicle speed to 30 mph.
6. The vehicle should be in second gearand overdrive clutch pressure shouldbelessthan5psi.
TEST FOUR - SELECTOR IN DRIVE (OD ON - Fourth Gear)
NOTE: This test checks the 2/4 clutch hydraulic circuit.
1. Attach gauge to the 2/4 clutch tap.
2. Move selector lever to the DRIVE position.
3. Allow vehicle front wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph.
Vehicleshouldbeinfourthgear.
4. The 2/4 clutch pressure should read 75 to 95 psi.
TEST FIVE-SELECTOR IN DRIVE (OD ON - Fourth Gear, CC on)
NOTE: These tests check the torque converter clutch hydraulic circuit.
1. Attach gauge to the torque converter clutch off pressure tap.
2. Move selector lever to the DRIVE position.
3. Allow vehicle wheels to turn and increase throttle opening to achieve anindicated vehicle speed of 50 mph.
Vehicle should be in 4th gear, CC on.
CAUTION: Both wheels must turn at the same speed.
4. Torque converter clutch off pressure should be less than 5 psi.
5. Now attach the gauge to the torque converter clutch on pressure tap.
6. Move selector to the OD position.
7. Allow vehicle wheels to turn and increase throttle opening to achieve anindicated vehicle speed of 50 mph.
8. Verify the torque converter clutch is applied mode using the RPM displayof the scan tool.
9. Torque converter clutch on pressure should be 60-90 psi.
TEST SIX-SELECTOR IN REVERSE
NOTE: This test checks the reverse clutch hydraulic circuit.
1. Attach gauge to the reverse and low/reverse clutch tap.
2. Move selector lever to the REVERSE position.
3. Read reverse clutch pressure with output stationary (foot on brake) andthrottle opened to achieve 1500 rpm.
4. Reverse and low/reverse clutch pressure should read 165 to 235 psi.
TEST RESULT INDICATIONS
1. If proper line pressure is found in any one test, the pump and pressure regulator are working properly.
2. Low pressure in all positions indicates a defective pump, a clogged filter, or a stuck pressure regulator valve.
3. Clutch circuit leaks are indicated if pressures do not fall within the specified pressure range.
4. If the overdrive clutch pressure is greater than 5 psi in Step 6 of Test Three, a worn reaction shaft seal ring or
a defective solenoid assembly is indicated.

MECHANISM-BRAKE TRANSMISSION SHIFT INTERLOCK
DESCRIPTION
The Brake Transmission Shifter Interlock (BTSI), is a
solenoid operated system. It consists of a solenoid
permanently mounted on the gearshift cable.
OPERATION
The system locks the shifter into the PARK position. The interlock system is engaged whenever the ignition switch
is in the LOCK or ACCESSORY position. An additional electrically activated feature will prevent shifting out of the
PARK position unless the brake pedal is depressed approximately one-halfan inch. A magnetic holding device in
line with the park lock cable is energized when the ignition is in the RUN position. When the key is in the RUN
position and the brake pedal is depressed, the shifter is unlocked and willmove into any position. The interlock
system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position, unless the shifter
is fully locked into the PARK position.
DIAGNOSIS AND TESTING - BRAKE TRANSMISSION SHIFT INTERLOCK
1. Verify that the key can only be removed in the PARK position.
2. When the shift lever is in PARK And the shift handle pushbutton is in the “OUT” position, the ignition key cylinder
should rotate freely from OFF to LOCK. When the shifter is in any other gear or neutral position, the ignition key
cylinder should not rotate to the LOCK position.
3. Shifting out of PARK should not be possible when the ignition key cylinder is in the OFF position.
4. Shifting out of PARK should not be possible while applying normal pushbutton force and ignition key cylinder is
in the RUN or START positions unless the foot brake pedal is depressed approximately 1/2 inch (12mm).
5. Shifting out of PARK should not be possible when the ignition key cylinderisintheACCESSORYorLOCK
positions.
6. Shifting between any gears, NEUTRAL or into PARK may be done without depressing foot brake pedal with
ignition switch in RUN or START positions.
ADJUSTMENTS - BRAKE TRANSMISSION SHIFT INTERLOCK
Correct cable adjustment is important to proper interlock operation. Thegearshift cable must be correctly adjusted
in order to shift out of PARK.

ADJUSTMENT PROCEDURE
1. Remove the steering column trim as necessary for
access to the brake transmission shift interlock.
2. Shift the transmission into the PARK position.
3. Pull upward on both the BTSI lock tab (4) and the
gearshift cable lock tab (3).
4. Verify that the shift lever is in the PARK position.
5. Verify positive engagement of the transmission
park lock by attempting to rotate the propeller
shaft. The shaft will not rotate when the park lock is
engaged.
6. Turn ignition switch to LOCK position.Be sure
ignition key cylinder is in the LOCK position.
Cable will not adjust correctly in any other
position.
7. Ensure that the cable is free to self-adjust by push-
ing cable rearward and releasing.
8. Push the gearshift cable lock tab (3) down until it snaps in place.
9. Locate the BTSI alignment hole in the bottom of the BTSI mechanism betweentheBTSIlocktabandtheBTSI
connector.
10. Move the BTSI assembly up or down on the gearshift cable until an appropriate size drill bit can be inserted into
the alignment hole and through the assembly.
11. Push the BTSI lock tab (4) down until it snaps into place and remove the drill bit.
12. Install any steering column trim previously removed.
BTSI FUNCTION CHECK
1. Verify removal of ignition key allowed in PARK position only.
2. When the shift lever is in PARK, the ignition key cylinder should rotate freely from off to lock. When the shifter
is in any other position, the ignition key should not rotate from off to lock.
3. Shifting out of PARK should be possible when the ignition key cylinder isin the off position.
4. Shifting out of PARK should not be possible while applying normal force,and ignition key cylinder is in the run
or start positions, unless the foot brake pedal is depressed approximately1/2inch(12mm).
5. Shifting out of PARK should not be possible when the ignition key cylinder is in the accessory or lock position.
6. Shifting between any gear and NEUTRAL, or PARK, may be done without depressing foot brake with ignition
switch in run or start positions.
7. Engine starts must be possible with shifter lever in PARK or NEUTRAL positions only. Engine starts must not be
possible in any position other than PARK or NEUTRAL.
8. With shifter lever in the:
PARK position - Apply upward force on the shift arm and remove pressure. Enginestartsmustbepossible.
PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible.
NEUTRAL position - Normal position. Engine starts must be possible.
NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission
shall not be able to shift from neutral to reverse.

FLUID LEVEL CHECK USING SCAN TOOL
NOTE: Engine and Transmission should be at normal operating temperature before performing this proce-
dure.
1. Start engine and apply parking brake.
2. Connect scan tool and select transmission.
3. Select sensors.
4. Read the transmission temperature value.
5. Compare the fluid temperature value with the chart.
6. Adjust transmission fluid level shown on the dipstick according to the 42RLE Fluid Temperature Chart. Use only
Mopar
ATF+4, Automatic Transmission Fluid.
7. Check transmission for leaks.
FLUID/FILTER SERVICE
NOTE: Only fluids of the type labeled MoparATF+4, Automatic Transmission Fluid, should be used in the
transmission sump. A filter change should be made at the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned with a clean, dry cloth.
NOTE: If the transmission is disassembled for any reason, the fluid and filter should be changed.
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transmission oil pan.
42RLE Fluid Temperature Chart

NOTE: One of the oil pan bolts (5) has a sealing
patch applied from the factory. Separate this bolt
for reuse.
2. Loosen pan bolts and tap the pan at one corner to
break it loose allowing fluid to drain, then remove
the oil pan.
3. Install a new filter and o-ring on bottom of the valve
body and tighten retaining screws to 5 Nꞏm (45 in.
lbs.).
NOTE: Before installing the oil pan bolt (5) in the
bolt hole located between the torque converter
clutch on and U/D clutch pressure tap circuits, it
will be necessary to replentish the sealing patch
on the bolt using Mopar
Lock & Seal Adhesive.
4. Clean the oil pan and magnet. Reinstall pan using
new Mopar
Silicone Adhesive sealant. Tighten oil
pan bolts to 20 Nꞏm (14.5 ft. lbs.).
5. Pour four quarts of Mopar
AT F + 4 , A u t o m a t i c
Transmission Fluid, through the dipstick opening.
6. Start engine and allow to idle for at least one minute. Then, with parkingand service brakes applied, move selec-
tor lever momentarily to each position, ending in the park or neutral position.
7. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to 3mm
(1/8 in.) below the lowest mark on the dipstick.
8. Recheck the fluid level after the transmission has reached normal operating temperature, 82° C (180°F).
9. To prevent dirt from entering transmission, make certain that dipstickis fully seated into the dipstick opening.
TRANSMISSION FILL
To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure:
1. Remove dipstick and insert clean funnel in transmission fill tube.
2. Add following initial quantity of Mopar
ATF+4totransmission:
a. If only fluid and filter were changed, add3 pints (1-1/2 quarts)of ATF +4 to transmission.
b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was
flushed, add12 pints (6 quarts)of ATF +4 to transmission.
3. Apply parking brakes.
4. Start and run engine at normal curb idle speed.
5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and
leave engine running at curb idle speed.
6. Remove funnel, insert dipstick andcheck fluid level. If level is low,add fluid to bring level to MIN mark on
dipstick.Check to see if the oil level is equal on both sides of the dipstick. If one side is noticably higher than
the other, the dipstick has picked up some oil from the dipstick tube. Allowthe oil to drain down the dipstick tube
and re-check.
7. Drive vehicle until transmission fluid is at normal operating temperature.
8. With the engine running at curb idle speed, the gear selector in NEUTRAL,and the parking brake applied, check
the transmission fluid level.
CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result.
9. Add fluid to bring level up to MAX arrow mark.
When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube.

CABLE-GEARSHIFT
DIAGNOSIS AND TESTING - GEARSHIFT CABLE
1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be
possible in any other gear position.
2. With the shift lever in the:
a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible.
b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be pos-
sible.
c. NEUTRAL position - Normal position. Engine starts must be possible.
d. NEUTRAL position - Engine running and brakes applied, apply upward forceontheshiftarm.Transmission
shall not be able to shift from neutral to reverse.
REMOVAL
1. Shift transmission into PARK.
2. Raise vehicle.
3. Disengage cable (1) eyelet at transmission manual
shift lever (3) and pull cable adjuster out of mount-
ing bracket.
4. Lower the vehicle.
5. Remove the dash panel insulation pad as neces-
sary to access the gearshift cable grommet (2).
6. Remove grommet (2) from the dash panel.

7. Remove any steering column (1) trim necessary to
access the gearshift cable (2) and BTSI mecha-
nism.
8. Disconnect the BTSI wiring connector (5).
9. Disconnect cable at lower column bracket and shift
lever pin and pull the cable through the dash panel
opening into the vehicle.
10. Remove gearshift cable (2) from vehicle.
INSTALLATION
1. Route the transmission end of the gearshift cable
(1) through the opening in the dash panel.
2. Seat the cable grommet (2) into the dash panel
opening.
3. Snap the cable into the steering column (1) bracket
so the retaining ears are engaged and snap the
cable eyelet onto the shift lever ball stud.
4. Raise the vehicle.
5. Place the transmission manual shift lever in the
“PARK” detent (rearmost) position and rotate prop
shaft to ensure transmission is in PARK.
6. Route the gearshift cable through the transmission
mounting bracket and secure the cable by snap-
ping the cable retaining ears into the transmission
bracket and snapping the cable eyelet on the man-
ual shift lever ball stud.
7. Lower vehicle.
8. Lock the shift cable adjustment by pressing the
cable adjuster lock tab (3) downward until it snaps
into place.
9. Check for proper operation of the transmission range sensor.
10. Adjust the gearshift cable (Refer to 21 - TRANSMISSION/AUTOMATIC/GEAR SHIFT CABLE - ADJUST-
MENTS) and BTSI mechanism (Refer to 21 - TRANSMISSION/AUTOMATIC/BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM - ADJUSTMENTS) as necessary.

When Monitored:
The transmission gear ratio is monitored continuously while the transmission is in gear.
Set Condition:
If there is an excessive change in output RPM in any gear. This DTC can take upto five minutes of problem
identification beforeilluminating the MIL.
Possible Causes
(T14) OUTPUT SPEED SENSOR SIGNAL CIRCUIT OPEN
(T13) SPEED SENSOR GROUND CIRCUIT OPEN
(T14) OUTPUT SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND
(T13) SPEED SENSOR GROUND CIRCUIT SHORT TO GROUND
(T14) OUTPUT SPEED SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE
(T13) SPEED SENSOR GROUND CIRCUIT SHORT TO VOLTAGE
OUTPUT SPEED SENSOR
POWERTRAIN CONTROL MODULE
Always perform the 45RFE/545RFE Pre-Diagnostic Troubleshooting Procedure before proceeding. (Refer to
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 45RFE/545RFE - STANDARD PROCEDURE)
Theory of Operation
The transmission system uses two speed sensors, one to measure input RPM and one to measure output RPM.
These inputs are essential for proper transmission operation. Therefore, the integrity of this data is verified through
the following checks:
1) When in gear, if the gear ratio does not compare to a known gear ratio, the corresponding in-gear trouble code
is set (codes P0731 through P0736).
2) An excessive change in input or output speeds indicating signal intermittent will result in codes P0715 and/or
P0720 being set.
3) If the common speed sensor ground circuit is lost, both sensor inputs will read the signal from the input speed
sensor at idle in neutral. Since the input speed sensor has 60 teeth and the output speed sensor has 30 teeth, this
results in a an apparent speed ratio of 1:2 and may cause the DTC P1794 to set.
Diagnostic Test
1.CHECK TO SEE IF DTC P0720 IS CURRENT
Turn the ignition off to the lock position.
CAUTION: Properly support the vehicle and raise all drive wheels off the ground.
Release the parking brake.
Start the engine in park.
Place the transmission gear selector in drive, release foot from brake.
WARNING: Be sure to keep hands and feet clear of rotation wheels.
With the scan tool, monitor the Output Speed Sensor RPM.
Is the Output Speed Sensor RPM below 100 RPM?
Ye s>>
Go To 2
No>>
Go To 9

2.CHECK IT THE DTC P0755 IS PRESENT
With the scan tool, check Transmission DTCs.
Is the DTC P0755 also present?
Ye s>>
Refer to the symptom list and perform diagnostics for P0755-2C SOLENOID CIRCUIT.
No>>
Go To 3
3.CHECK IF THE DTCS P0732, P0735 AND/OR P0846 ARE PRESENT
With the scan tool, check for other transmission DTCs.
Are the DTCs P0732, P0735, and/or P0846 present also?
Ye s>>
Go To 12
No>>
Go To 4
4.CHECK TO SEE IF DTC P0845 IS CURRENT
With the scan tool, Check the STARTS SINCE SET counter for P0845.
NOTE: This counter only applies to the last DTC set.
Is the STARTS SINCE SET counter 2 or less?
Ye s>>
Go To 5
No>>
Go To 17
5.CHECK IF THE LINE PRESSURE STAYS THE SAME
Start the engine.
Warm the transmission to 82° C or 180° F.
Firmly apply the brakes.
With the scan tool, monitor the Line Pressure during the following step.
Move the shift lever to each gear position, pausing momentarily in each position and record the line pressure read-
ing. Allow the pressure to stabilize for at least 5 seconds in each range.
Did the line pressure remain at a steady value between 585 and 655 kPa or 85 and 95 psi in each posi-
tion?
Ye s>>
Go To 6
No>>
Go To 10
6.CHECK THE LINE PRESSURE SENSOR CONNECTION
Ignition on,engine not running.
Withthescantool,monitortheLinePressure while firmly pushing the Transmission Line Pressure Sensor connector
inwards towards the Transmission.
Did the Line Pressure reading on the scan tool change to about 207 kPa or 30 psi when the connector
was pushed inward?
Ye s>>
Disconnect and properly reconnect the Line Pressure Sensor connector. Inspect terminals and repair as
necessary.
Perform 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1. (Refer to 21- TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - 45RFE/545RFE - STANDARD PROCEDURE)
No>>
Go To 7