lock DODGE RAM SRT-10 2006 Service Repair Manual

GEAR CASE
1. Position park pawl and spring in case and install
park pawl shaft. Verify that end of spring with 90°
bend is hooked to pawl and straight end of spring
is seated against case.
2. Install pawl shaft retaining bolt. Tighten bolt to 27
Nꞏm (20 ft. lbs.) torque.
3. Install park lock reaction plug (3). Note that plug
has locating pin (2) at rear. Be sure pin is seated in
hole in case before installing snap-ring (1).
4. Install reaction plug snap-ring (1). Compress snap-
ring only enough for installation; do not distort it.
5. Verify that tab ends of rear bearing locating ring (2)
extend into access hole (1) in gear case.

6. Support geartrain on Tool 6227-1. Be sure tool is
securely seated in clutch hub.
7. Install overdrive gear case (2) on geartrain (1).
8. Expand front bearing locating ring with snap-ring
pliers (1). Then slide case downward until locating
ring locks in bearing groove and release snap-ring.
9. Install locating ring access cover, gasket and
screws (2) in overdrive unit case.
OVERDRIVE CLUTCH
NOTE: The overdrive clutch in a 48RE transmis-
sion uses 5 or 6 clutch discs depending on the
application.
1. Install overdrive clutch reaction ring (1) first. Reac-
tion ring is flat with notched ends.

2. For 5 disc overdrive clutch versions, install wave
spring (1) on top of reaction ring. Reaction ring and
waveringbothfitinsameringgroove.Usescrew-
driver to seat each ring securely in groove. Also
ensure that the ends of the two rings are offset
from each other.
3. Assemble overdrive clutch pack.
4. Install overdrive clutch reaction plate first.
5. Install first clutch disc followed by first clutch plate.
Then install remaining clutch discs and plates in
same order.
6. Install clutch pack pressure plate.
7. Install clutch pack wire-type retaining ring (1).
INTERMEDIATE SHAFT SPACER SELECTION
1. Place overdrive unit in vertical position. Mount it on
blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be
sure output shaft is not loaded and internal compo-
nents are moved rearward for accurate measure-
ment.
2. Determine correct thickness intermediate shaft
spacer as follows:
a. Insert Gauge 6312 (1) through sun gear, plan-
etary gear and into pilot bushing in output
shaft. Be sure tool bottoms against planetary
shoulder.
b. Position Gauge Bar 6311 (2) across face of
overdrive case. Then position Dial Caliper over
gauge tool.
c. Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge 6312
(1). Lock scale in place. Remove dial caliper tool and note distance measured.

3. Select proper thickness end play spacer from
spacer chart based on distance measured.
4. Remove Gauge Alignment Tool 6312.
OD THRUST PLATE SELECTION
1. Place overdrive unit in vertical position. Mount it on
blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be
sure output shaft is not loaded and internal compo-
nents are moved rearward for accurate measure-
ment.
2. Determine correct thickness overdrive piston thrust
plate as follows:
a. Position Gauge Tool 6311 (1) across face of
overdrive case. Then position Dial Caliper over
gauge tool.
b. Measure distance to clutch hub thrust bearing
seat (2) at four points 90° apart. Then average
measurements by adding them and dividing by
4.
3. Select and install required thrust plate from infor-
mation in thrust plate chart.
4. Leave Alignment Tool 6227-2 in place. Tool will
keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on trans-
mission.
5. Transmission speed sensor can be installed at this
time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.
OVERDRIVE PISTON
1. Install new seals on overdrive piston.
2. Stand transmission case upright on bellhousing.
3. Position Guide Ring 8114-1 on outer edge of overdrive piston retainer.
4. Position Seal Guide 8114-3 on inner edge of overdrive piston retainer.
5. Install overdrive piston in overdrive piston retainer by:
a. Aligning locating lugs on overdrive piston to the two mating holes in retainer.
b. Lubricate overdrive piston seals with Mopar
ATF+4.
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.
6. Install intermediate shaft spacer on intermediate shaft.
7. Install overdrive piston thrust plate on overdrive piston.
8. Install overdrive piston thrust bearing on overdrive piston.
9. Install transmission speed sensorand o-ring seal in overdrive case.
INSTALLATION
1. Be sure overdrive unit Alignment Tool 6227-2 is
fully seated before moving unit. If tool is not seated
and gear splines rotate out of alignment, overdrive
unit will have to be disassembled in order to realign
splines.
2. If overdrive piston retainer was not removed during
service and original case gasket is no longer reus-
able, prepare new gasket by trimming it.
3. Cut out old case gasket (1) around piston retainer
with razor knife (2).
4. Use old gasket as template and trim new gasket to
fit.
5. Position new gasket over piston retainer and on
transmission case. Use petroleum jelly to hold gas-
ket in place if necessary. Do not use any type of
sealer to secure gasket. Use petroleum jelly only.
6. Install selective spacer (1) on intermediate shaft
(3), if removed. Spacer goes in groove just rear-
ward of shaft rear splines.
7. Install thrust bearing in overdrive unit sliding hub. Use petroleum jelly to hold bearing in position.
CAUTION: Be sure the shoulder on the inside diameter of the bearing is facingforward.
8. Verify that splines in overdrive planetary gear and overrunning clutchhub are aligned with Alignment Tool 6227-2.
Overdrive unit cannot be installed if splines are not aligned. If splines have rotated out of alignment, unit will
have to be disassembled to realign splines.
9. Carefully slide Alignment Tool 6227-2 out of overdrive planetary gear and overrunning clutch splines.
10. Raise overdrive unit and carefully slide it straight onto intermediate shaft. Insert park rod into park lock reaction
plug at same time. Avoid tilting overdrive during installation as this could cause planetary gear and overrunning
clutch splines to rotate out of alignment. If this occurs, it will be necessary to remove and disassemble overdrive
unit to realign splines.
11. Work overdrive unit forward on intermediate shaft until seated against transmission case.
12. Install bolts attaching overdrive unit to transmission unit. Tightenbolts in diagonal pattern to 34 Nꞏm (25 ft-lbs).
13. Connect the transmission speed sensor and overdrive wiring connectors.
14. Install the transfer case, if equipped. (Refer to 21 - TRANSMISSION/TRANSAXLE/TRANSFER CASE - INSTAL-
LATION)

RETAINER-OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON
DESCRIPTION
The overrunning clutch consists of an inner race (5),
an outer race (or cam) (1), rollers (2) and springs (3),
and the spring retainer (4). The number of rollers and
springs depends on what transmission and which
overrunning clutch is being dealt with.
OPERATION
Astheinnerraceisrotatedinaclockwisedirection(asviewedfromthefront of the transmission), the race causes
the rollers to roll toward the springs, causing them to compress against their retainer. The compression of the
springs increases the clearance between the rollers and cam. This increased clearance between the rollers and cam
results in a freewheeling 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 thesprings. 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 (1).
2. Remove the overdrive piston retainer bolts.
3. Remove overdrive piston retainer (4).
4. Remove case gasket.

16. Turn planetary geartrain over. Position wood block
under front end of intermediate shaft and support
geartrain on shaft. Be sure all geartrain parts
have moved forward against planetary snap-ring.
This is important for accurate end play check.
17. Check planetary geartrain end play with feeler
gauge (3). Insert gauge between rear annulus
gear (2) and shoulder on intermediate shaft (1) as
shown. End play should be 0.15 to 1.22 mm
(0.006 to 0.048 in.).
18. If end play is incorrect, install thinner/thicker plan-
etary snap-ring as needed.

DISASSEMBLY
1. Remove fiber thrust washer (18) from forward side of clutch retainer (1).
2. Remove input shaft front and rear seal rings (2).
3. Remove selective clutch pack snap-ring (10).
4. Remove the reaction plate (11), clutch discs (9), steel plates (12), pressure plate (8), wave spring (13), spacer
ring (14), and piston spring (7).
5. Remove clutch piston (15) with rotating motion.
6. Remove and discard piston seals (6, 16).
7. Remove input shaft retaining ring (19). It may be necessary to press the input shaft in slightly to relieve tension
on the retaining ring
8. Press input shaft out of retainer with shop press and suitable size presstool. Use a suitably sized press tool to
support the retainer as close to the input shaft as possible.
CLEANING
Clean the clutch components with solvent and dry them with compressed air.Do not use rags or shop towels to dry
any of the clutch parts. Lint from such materials will adhere to component surfaces and could restrict or block fluid
passages after assembly.
Rear Clutch Components
1 - REAR CLUTCH RETAINER 11 - REACTION PLATE
2 - TORLON™ SEAL RINGS 12 - CLUTCH PLATES
3 - INPUT SHAFT 13 - WAVE SPRING
4 - PISTON RETAINER 14 - SPACER RING
5 - OUTPUT SHAFT THRUST WASHER 15 - PISTON
6 - INNER PISTON SEAL 16 - OUTER PISTON SEAL
7 - PISTON SPRING 17 - REAR SEAL RING
8 - PRESSURE PLATE 18 - FIBER THRUST WASHER
9 - CLUTCH DISCS 19 - RETAINING RING
10 - SNAP-RING (SELECTIVE)

INSPECTION
Replace the clutch discs if warped, worn, scored, burned/charred, the lugs are damaged, or if the facing is flaking
off. Replace the top and bottom pressure plates if scored, warped, or cracked. Be sure the driving lugs on the
pressure and clutch plates are also in good condition. The lugs must not be bent, cracked or damaged in any way.
Replace the piston spring and wave spring if either part is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The clutch and pressure plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged. Also check action of the check balls in the retainer and piston.
Each check ball must move freely and not stick.
Replace the retainer bushing if worn, scored, or doubt exists about bushing condition.
Inspect the piston and retainer seal surfaces for nicks or scratches. Minor scratches can be removed with crocus
cloth. However, replace the piston and/or retainer if the seal surfaces are seriously scored.
Check condition of the fiber thrust washer and metal output shaft thrust washer. Replace either washer if worn or
damaged.
Check condition of the seal rings on the input shaft and clutch retainer hub. Replace the seal rings only if worn,
distorted, or damaged. The input shaft front seal ring is teflon with chamfered ends. The rear ring is metal with
interlocking ends.
Check the input shaft for wear, or damage. Replace the shaft if worn, scoredor damaged in any way.
ASSEMBLY
1. Soak clutch discs in transmission fluid while
assembling other clutch parts.
2. Install new seal rings on clutch retainer hub and
input shaft if necessary.
a. Be sure clutch hub seal ring is fully seated in
groove and is not twisted.
3. Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then partially press
input shaft (1) into retainer (2). Use a suitably sized
press tool to support retainer as close to input shaft
as possible.
4. Install input shaft retaining ring.
5. Press the input shaft the remainder of the way into
the clutch retainer.

ACTUATOR-THROTTLE VALVE
DESCRIPTION
On vehicles equipped with a Cummins diesel engine,
the transmission throttle valve cable has been replace
by the transmission throttle valve actuator (TTVA). The
TTVA consists of an electric DC motor, two potentiom-
eters, and a gear drive system. The TTVA is mechan-
ically connected to the transmission throttle valve in
the valve body by the “D” shaped opening in the bot-
tom of the TTVA shaft. Changes in the TTVA position
are therefore transferred to the throttle valve and
cause changes in the transmission throttle pressure.
REMOVAL
1. Remove the bolts (2) holding the transmission
throttle valve actuator (TTVA) (1) to the transmis-
sion case.
2. Allow the TTVA (1) to rotate clockwise away from
the transmission.