engine DODGE RAM SRT-10 2006 Service Repair Manual

PRE-DIAGNOSTIC CHECKOUT (DIESEL)
For a complete wiring diagramRefer to Section 8W
1.PRE-DIAGNOSTIC CHECKOUT
NOTE: Always perform diagnostics with a fully charged battery to avoid false symptoms.
NOTE: Low fluid level can be the cause of many transmission problems. If thefluid level is low locate and
repair the leak then check and adjust the fluid level per the Service Information.
With the scan tool, read engine DTC’s. Check and repair all engine DTCs prior to performing transmission symptom
diagnostics.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors. Repair as necessary.
Verify the flash level of the Engine Control Module. Some problems are corrected by software upgrades.
Check for any Service Information Tune-ups or Technical Service Bulletins that may apply.
Did any of the above checks or procedures correct the symptom?
Ye s>>
Repair is complete.
Perform RE TRANSMISSION VERIFICATION TEST VER - 1 (DIESEL). (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 48RE - STANDARD PROCEDURE)
No>>
Refer to the Transmission category and perform the appropriate symptom(s).

CLEANING ................................. 1389
INSPECTION ............................... 1389
ASSEMBLY . ............................... 1390
INSTALLATION ............................. 1400
RETAINER-OVERRUNNING CLUTCH CAM/
OVERDRIVE PISTON
DESCRIPTION ............................. 1402
OPERATION ............................... 1402
DISASSEMBLY ............................. 1402
CLEANING ................................. 1403
INSPECTION ............................... 1403
ASSEMBLY . ............................... 1403
SHAFT-PLANETARY GEARTRAIN/OUTPUT
DESCRIPTION ............................. 1407
OPERATION ............................... 1407
DISASSEMBLY ............................. 1407
INSPECTION ............................... 1410
ASSEMBLY ................................ 1410
CLUTCH-REAR
DESCRIPTION ............................. 1416
OPERATION ............................... 1416
DISASSEMBLY ............................. 1417
CLEANING ................................. 1417
INSPECTION ............................... 1418
ASSEMBLY ................................ 1418
SERVO-REAR
DESCRIPTION ............................. 1421
OPERATION ............................... 1421
DISASSEMBLY ............................. 1421
CLEANING ................................. 1421
ASSEMBLY ................................ 1421
MECHANISM-SHIFT
DESCRIPTION ............................. 1422
OPERATION ............................... 1422
SENSOR-SPEED
DESCRIPTION ............................. 1423
OPERATION ............................... 1423
ACTUATOR-THROTTLE VALVE
DESCRIPTION ............................. 1424
REMOVAL ................................. 1424
INSTALLATION ............................. 1425
ADJUSTMENTS
ADJUSTMENT ............................ 1426
CABLE-THROTTLE VALVE
DESCRIPTION ............................. 1427ADJUSTMENTS - THROTTLE VALVE CABLE . . 1428
CONVERTER-TORQUE
DESCRIPTION ............................. 1431
OPERATION ............................... 1435
REMOVAL ................................. 1436
INSTALLATION ............................. 1437
VALVE-TORQUE CONVERTER DRAINBACK
DESCRIPTION
GAS ENGINES ........................... 1438
DIESEL ENGINE .......................... 1438
OPERATION
GAS ENGINES ........................... 1438
DIESEL ENGINE .......................... 1438
STANDARD PROCEDURE
GAS ENGINES ........................... 1438
DIESEL ENGINE .......................... 1438
SWITCH-TOW/HAUL OVERDRIVE
DESCRIPTION ............................. 1440
OPERATION ............................... 1440
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS ................. 1440
REMOVAL ................................. 1440
INSTALLATION ............................. 1441
SENSOR-TRANSMISSION RANGE
DESCRIPTION ............................. 1442
OPERATION ............................... 1442
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS) ................... 1443
REMOVAL ................................. 1444
INSTALLATION ............................. 1445
SENSOR-TRANSMISSION TEMPERATURE
DESCRIPTION ............................. 1447
OPERATION ............................... 1447
BODY-VALVE
DESCRIPTION ............................. 1448
OPERATION ............................... 1451
REMOVAL ................................. 1471
DISASSEMBLY ............................. 1472
CLEANING ................................. 1485
INSPECTION ............................... 1485
ASSEMBLY................................ 1486
INSTALLATION ............................. 1497
ADJUSTMENTS - VALVE BODY .............. 1498

The 48RE is a four speed fully automatic transmissions with an electronic governor. The 48RE is equipped with a
lock-up clutch in the torque converter. First through third gear ranges are provided by the clutches, bands, over-
running clutch, and planetary gear sets in the transmission. Fourth gear range is provided by the overdrive unit that
contains an overdrive clutch, direct clutch, planetary gear set, and overrunning clutch.
The transmission contains a front, rear, and direct clutch which functionas the input driving components. It also
contains the kickdown (front) and the low/reverse (rear) bands which, along with the overrunning clutch and over-
drive clutch, serve as the holding components. The driving and holding components combine to select the neces-
sary planetary gear components, in the front, rear, or overdrive planetary gear set, transfer the engine power from
the input shaft through to the output shaft.
The valve body is mounted to the lower side of the transmission and containsthe valves to control pressure reg-
ulation, fluid flow control, and clutch/band application. The oil pump ismounted at the front of the transmission and
is driven by the torque converter hub. The pump supplies the oil pressure necessary for clutch/band actuation and
transmission lubrication.
IDENTIFICATION
Transmission identification numbers (1) are stamped
on the left side of the case just above the oil pan gas-
ket surface. Refer to this information when ordering
replacement parts.
GEAR RATIOS
The 48RE gear ratios are:
.............................................................................. 2.45:1
............................................................................. 1.45:1
.............................................................................. 1.00:1
.............................................................................. 0.69:1
............................................................................. 2.20:1
1 - TORQUE CONVERTER 10 - OVERDRIVE CLUTCH
2 - INPUT SHAFT 11 - DIRECT CLUTCH
3 - OIL PUMP 12 - PLANETARY GEAR
4 - FRONT BAND 13 - INTERMEDIATE SHAFT
5 - FRONT CLUTCH 14 - OVERDRIVE OVERRUNNING CLUTCH
6 - REAR CLUTCH 15 - DIRECT CLUTCH SPRING
7 - PLANETARIES 16 - OVERDRIVE PISTON RETAINER
8 - REAR BAND 17 - OIL PAN
9 - OVERRUNNING CLUTCH 18 - VALVE BODY

OPERATION
The application of each driving or holding component is controlled by the valve body based upon the manual lever
position, throttle pressure, and governor pressure. The governor pressure is a variable pressure input to the valve
body and is one of the signals that a shift is necessary. First through fourth gear are obtained by selectively apply-
ing and releasing the different clutches and bands. Engine power is thereby routed to the various planetary gear
assemblies which combine with the overrunning clutch assemblies to generate the different gear ratios. The torque
converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque
converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain
Control Module (PCM). The torque converter clutch engages in fourth gear,and in third gear under various condi-
tions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has
warmed up. The torque converter clutch can also be engaged in the MANUAL SECOND gear position if high trans-
mission temperatures are sensed by the PCM. The torque converter clutch will disengage momentarily when an
increase in engine load is sensed by the PCM, such as when the vehicle beginsto go uphill or the throttle pressure
is increased. The torque converter clutch feature increases fuel economyand reduces the transmission fluid tem-
perature.
Since the overdrive clutch is applied in fourth gear only and the direct clutch is applied in all ranges except fourth
gear, the transmission operation for park, neutral, and first through third gear will be described first. Once these
powerflows are described, the third to fourth shift sequence will be described.
PARK POWERFLOW
As the engine is running and the crankshaft is rotat-
ing, the flexplate and torque converter, which are also
bolted to it, are all rotating in a clockwise direction as
viewed from the front of the engine. The notched hub
of the torque converter is connected to the oil pump’s
internal gear, supplying the transmission with oil pres-
sure. As the converter turns, it turns the input shaft in
a clockwise direction. As the input shaft is rotating, the
front clutch hub-rear clutch retainer and all their asso-
ciated parts are also rotating, all being directly con-
nected to the input shaft. The power flow from the
engine through the front clutch hub and rear clutch
retainer stops at the rear clutch retainer. Therefore, no
power flow to the output shaft occurs because no
clutches are applied. The only mechanism in use at
this time is the parking sprag (1), which locks the
parking gear (2) on the output shaft (3) to the trans-
mission case.

REVERSE POWERFLOW
When the gear selector is moved into the REVERSE position, the front clutch(1, 7) and the rear band (3, 8) are
applied. With the application of the front clutch, engine torque (4, 6) is applied to the sun gear, turning it in a clock-
wise direction. The clockwise rotation of the sun gear causes the rear planet pinions to rotate against engine rota-
tion in a counterclockwise direction. The rear band is holding the low reverse drum, which is splined to the rear
carrier. Since the rear carrier is being held, the torque from the planet pinions is transferred to the rear annulus
gear, which is splined to the output shaft (2, 5). The output shaft in turn rotates with the annulus gear in a coun-
terclockwise direction giving a reverse gear output. The entire transmission of torque is applied to the rear planetary
gearset only. Although there is torque input to the front gearset through the sun gear, no other member of the gear-
set is being held. During the entire reverse stage of operation, the front planetary gears are in an idling condition.
Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED

FIRST GEAR POWERFLOW
When the gearshift lever is moved into the DRIVE position the transmissiongoes into first gear. As soon as the
transmission is shifted from PARK or NEUTRAL to DRIVE, the rear clutch applies (3, 7), applying the rear clutch
pack to the front annulus gear. Engine torque (6, 8) is now applied to the front annulus gear turning it in a clockwise
direction. With the front annulus gear turning in a clockwise direction, it causes the front planets to turn in a clock-
wise direction. The rotation of the front planets cause the sun to revolve in a counterclockwise direction. The sun
gear now transfers its counterclockwise rotation to the rear planets which rotate back in a clockwise direction. With
the rear annulus gear stationary, the rear planet rotation on the annulus gear causes the rear planet carrier to
revolve in a counterclockwise direction. The rear planet carrier is splined into the low-reverse drum, and the low
reverse drum is splined to the inner race of the over-running clutch (2, 5).With the over-running clutch locked, the
planet carrier is held, and the resulting torque provided by the planet pinions is transferred to the rear annulus gear.
The rear annulus gear is splined to the output shaft (1, 4) and rotated alongwith it (clockwise) in an underdrive gear
reduction mode.
First Gear Powerflow
1 - OUTPUT SHAFT 5 - OVER-RUNNING CLUTCH HOLDING
2 - OVER-RUNNING CLUTCH HOLDING 6 - INPUT SHAFT
3 - REAR CLUTCH APPLIED 7 - REAR CLUTCH APPLIED
4 - OUTPUT SHAFT 8 - INPUT SHAFT

SECOND GEAR POWERFLOW
In DRIVE-SECOND, the same elements are applied as in MANUAL-SECOND. Therefore, the power flow will be the
same, and both gears will be discussed as one in the same. In DRIVE-SECOND, the transmission has proceeded
from first gear to its shift point, and is shifting from first gear to second. The second gear shift is obtained by keep-
ing the rear clutch applied ((3, 7) and applying the front (kickdown) band (1, 8). The front band holds the front clutch
retainer that is locked to the sun gear driving shell. With the rear clutch still applied, the input is still on the front
annulus gear turning it clockwise at engine speed. Now that the front band is holding the sun gear stationary, the
annulus rotation causes the front planets to rotate in a clockwise direction. The front carrier is then also made to
rotate in a clockwise direction but at a reduced speed. This will transmit the torque to the output shaft (2, 4), which
is directly connected to the front planet carrier. The rear planetary annulus gear will also be turning because it is
directly splined to the output shaft. All power flow has occurred in the front planetary gear set during the drive-
second stage of operation, and now the over-running clutch, in the rear of the transmission, is disengaged and
freewheeling on its hub.
Second Gear Powerflow
1 - KICKDOWN BAND APPLIED 6 - INPUT SHAFT
2 - OUTPUT SHAFT 7 - REAR CLUTCH APPLIED
3 - REAR CLUTCH ENGAGED 8 - KICKDOWN BAND APPLIED
4 - OUTPUT SHAFT 9 - INPUT SHAFT
5 - OVER-RUNNING CLUTCH FREE-WHEELING

DIRECT DRIVE POWERFLOW
The vehicle has accelerated and reached the shift point for the 2-3 upshiftinto direct drive. When the shift takes
place, the front band is released, and the front clutch is applied (1, 9). The rear clutch stays applied (4, 8) as it has
been in all the forward gears. With the front clutch now applied, engine torque is now on the front clutch retainer,
which is locked to the sun gear drivingshell. This means that the sun gear isnow turning in engine rotation (clock-
wise) and at engine speed. The rear clutch is still applied so engine torque(6, 10) is also still on the front annulus
gear. If two members of the same planetary set are driven, direct drive results. Therefore, when two members are
rotating at the same speed and in the same direction, it is the same as being locked up. The rear planetary set is
also locked up, given the sun gear is still the input, and the rear annulus gear must turn with the output shaft (3, 5).
Both gears are turning in the same direction and at the same speed. The frontand rear planet pinions do not turn
at all in direct drive. The only rotation is the input from the engine to the connected parts, which are acting as one
common unit, to the output shaft.
FOURTHGEARPOWERFLOW
Fourth gear overdrive range is electronically controlled and hydraulically activated. Various sensor inputs are sup-
plied to the powertrain control module to operate the overdrive solenoid on the valve body. The solenoid contains a
check ball that opens and closes a vent port in the 3-4 shift valve feed passage. The overdrive solenoid (and check
ball) are not energized in first, second, third, or reverse gear. The vent port remains open, diverting line pressure
from the 2-3 shift valve away from the 3-4 shift valve. The Tow/Haul controlswitch must be in the ON position to
transmit overdrive status to the PCM. A 3-4 upshift occurs only when the overdrive solenoid is energized by the
PCM. The PCM energizes the overdrive solenoid during the 3-4 upshift. Thiscauses the solenoid check ball to close
the vent port allowing line pressure from the 2-3 shift valve to act directly on the 3-4 upshift valve. Line pressure on
the 3-4 shift valve overcomes valve spring pressure moving the valve to theupshift position. This action exposes
the feed passages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 accumulator, and ultimately to the overdrive pis-
ton. Line pressure through the timing valve moves the overdrive piston into contact with the overdrive clutch. The
direct clutch is disengaged before the overdrive clutch is engaged. The boost valve provides increased fluid apply
Direct Drive Powerflow
1 - FRONT CLUTCH APPLIED 6 - INPUT SHAFT
2 - OVER-RUNNING CLUTCH FREE-WHEELING 7 - OVER-RUNNING CLUTCH FREE-WHEELING
3 - OUTPUT SHAFT 8 - REAR CLUTCH APPLIED
4 - REAR CLUTCH APPLIED 9 - FRONT CLUTCH APPLIED
5 - OUTPUT SHAFT 10 - INPUT SHAFT

pressure to the overdrive clutch during 3-4 upshifts, and when accelerating in fourth gear. The 3-4 accumulator
cushions overdrive clutch engagement to smooth 3-4 upshifts. The accumulator is charged at the same time as
apply pressure acts against the overdrive piston.
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION
Automatic transmission problems can be a result of poor engine performance, incorrect fluid level, incorrect linkage
or cable adjustment, band or hydraulic control pressure adjustments, hydraulic system malfunctions or electrical/
mechanical component malfunctions. Begin diagnosis by checking the easily accessible items such as: fluid level
and condition, linkage adjustments and electrical connections. A road test will determine if further diagnosis is nec-
essary.
PRELIMINARY
Two basic procedures are required. One procedure for vehicles that are drivable and an alternate procedure for
disabled vehicles (will not back up or move forward).
VEHICLE IS DRIVEABLE
1. Check for transmission fault codes using DRBscan tool.
2. Check fluid level and condition.
3. Adjust throttle and gearshift linkage if complaint was based on delayed, erratic, or harsh shifts.
4. Road test and note how transmission upshifts, downshifts, and engages.
5. Perform hydraulic pressure test if shift problems were noted during roadtest.
6. Perform air-pressure test to check clutch-band operation.
VEHICLE IS DISABLED
1. Check fluid level and condition.
2. Check for broken or disconnected gearshift or throttle linkage.
3. Check for cracked, leaking cooler lines, or loose or missing pressure-port plugs.
4. Raise and support vehicle on safety stands, start engine, shift transmission into gear, and note following:
a. If propeller shaft turns but wheels do not, problem is with differentialor axle shafts.
b. If propeller shaft does not turn and transmission is noisy, stop engine.Remove oil pan, and check for debris.
If pan is clear, remove transmission and check for damaged drive plate, converter, oil pump, or input shaft.
c. If propeller shaft does not turn and transmission is not noisy, perform hydraulic-pressure test to determine if
problem is hydraulic or mechanical.
ROAD TESTING
Before road testing, be sure the fluid level and control cable adjustmentshave been checked and adjusted if nec-
essary. Verify that diagnostic trouble codes have been resolved.
Observe engine performance during the road test. A poorly tuned engine will not allow accurate analysis of trans-
mission operation.
Operate the transmission in all gear ranges. Check for shift variations and engine flare which indicates slippage.
Note if shifts are harsh, spongy, delayed, early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means clutch, band or overrunning clutch problems. If the condition is
advanced, an overhaul will be necessary to restore normal operation.
A slipping clutch or band can often be determined by comparing which internal units are applied in the various gear
ranges. The Clutch and Band Application chart provides a basis for analyzing road test results.
Clutch and Band Application Chart

Pressure Test Port Locations
Test ports are located at both sides of the transmis-
sion case.
Line pressure is checked at the accumulator port (3)
on the right side of the case. The front servo pressure
port (4) is at the right side of the case just behind the
filler tube opening.
The rear servo (1) and governor pressure (2) ports are
at the right rear of the transmission case. The over-
drive clutch pressure port (5) is at the left rear of the
case.
Test One - Transmission In Manual Low
This test checks pump output, pressure regulation, and condition of the rear clutch and servo circuit. Both test
gauges are required for this test.
1. Connect tachometer to engine. Position tachometer so it can be observedfrom driver seat if helper will be oper-
ating engine. Raise vehicle on hoist that will allow rear wheels to rotate freely.
2. Connect 100 psi Oil Pressure Gauge C-3292 to accumulator port. Then connect 300 psi Oil Pressure Gauge
C-3293-SP to rear servo port.
3. Disconnect throttle and gearshift cables from levers on transmission valve body manual shaft.
4. Have helper start and run engine at 1000 rpm.
5. Move transmission shift lever fully forward into 1 range.
6. Gradually move transmission throttle lever from full forward to full rearward position and note pressures on both
gauges:
Line pressure at accumulator port should be 54-60 psi (372-414 kPa) with throttle lever forward and gradually
increase to 90-96 psi (621-662 kPa) as throttle lever is moved rearward.
Rear servo pressure should be same asline pressure within 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
This test checks pump output, line pressure and pressure regulation. Use 100 psi Oil Pressure Gauge C-3292 for
this test.
1. Leave vehicle in place on hoist and leave Oil Pressure Gauge C-3292 connected to accumulator port.
2. Have helper start and run engine at 1000 rpm.
3. Move transmission shift lever one detent rearward from full forward position. This is 2 range.
4. Move transmission throttle lever from full forward to full rearward position and read pressure on gauge.