Chrysler 45RFE User Manual

Reprinted

August, 2006

INTRODUCTION

CHRYSLER 45RFE

Beginning at the start of production for the 1999 model year Chrysler Corporation has introduced a brand new rear wheel drive transmission for the 99 Jeep Grand Cherokee with the 4.7L engine, and scheduled for the Ram Pick-up for the 2000 model year. This is the first completely new rear wheel drive automatic transmission from Chrysler in more than thirty years. The 45RFE designation tells us that this new unit has 4 forward speeds, a relative torque rating of 5, is for Rear drive vehicles and is Fully Electronic controlled. Refer to Figure 1. The 545RFE was introduced in 2003 in 3.7 and 5.7 engines. There are few differences in the components between the 45RFE and the 545RFE, although the main difference is the addition of a fifth ratio, which is electronically controlled.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts.

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

DALE ENGLAND

FIELD SERVICE CONSULTANT

PETER LUBAN

TECHNICAL CONSULTANT

JON GLATSTEIN

TECHNICAL CONSULTANT

ROLAND ALVAREZ

TECHNICAL CONSULTANT

GERALD CAMPBELL

TECHNICAL CONSULTANT

GABE DE LOS REYES

TECHNICAL CONSULTANT

WAYNE COLONNA

PRESIDENT

JIM DIAL

TECHNICAL CONSULTANT

ED KRUSE

TECHNICAL CONSULTANT

GREGORY LIPNICK

TECHNICAL CONSULTANT

DAVID CHALKER

TECHNICAL CONSULTANT

GREG CATANZARO

TECHNICAL CONSULTANT

RICHARD GRAHAM

TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

1

CH RYS LER 4 5R FE

CH RYS LER 5 45 RFE

INDEX

CLUTCH APPLICATION CHART ......................................................................................................................

SOLENOID ON/OFF CHART ...............................................................................................................................

CASE CONNECTOR AND TCM PIN CAVITY IDENTIFICATION ...............................................................

WIRING SCHEMATIC ..........................................................................................................................................

CONTROL RELAY AND FUSE LOCATIONS ...................................................................................................

TRS/SOLENOID BODY TESTS ...........................................................................................................................

OBDII DIAGNOSTIC TROUBLE CODE IDENTIFICATION .........................................................................

OIL PASSAGE IDENTIFICATION ......................................................................................................................

LINE PRESSURE TESTING .................................................................................................................................

GENERAL TRANSMISSION OPERATION INFORMATION ........................................................................

TRANSMISSION DISASSEMBLY PROCEDURE .............................................................................................

COMPONENT REBUILD PROCESS

TRANSMISSION CASE ASSEMBLY ..............................................................................................................

LOW/REVERSE CLUTCH HOUSING ASSEMBLY .....................................................................................

2-4 CLUTCH RETAINER ASSEMBLY ...........................................................................................................

GEAR TRAIN COMPONENTS ........................................................................................................................

INPUT CLUTCH HOUSING ASSEMBLY ......................................................................................................

INPUT CLUTCH HOUSING SNAP RING IDENTIFICATION ...................................................................

OIL PUMP ASSEMBLY INCLUDING VALVES ............................................................................................

VALVE BODY ASSEMBLY ...............................................................................................................................

TRANSMISSION FINAL ASSEMBLY PROCEDURE ......................................................................................

CHECKING FRONT END PLAY .........................................................................................................................

AIR PRESSURE TESTS ........................................................................................................................................

END PLAY SPECIFICATIONS ............................................................................................................................

FLUID SPECIFICATIONS ....................................................................................................................................

TORQUE SPECIFICATIONS AND BOLT IDENTIFICATION .......................................................................

EXPLODED ILLUSTRATIONS OF INTERNAL PARTS .................................................................................

THRUST BEARING CHART ................................................................................................................................

SPECIAL TOOLS ...................................................................................................................................................

545RFE DIAGNOSTIC TROUBLE CODES..........................................................................................................

NGC MODELS WIRING SCHEMATIC.................................................................................................................

NGC CONNECTOR I.D. AND LOCATIONS............................................................................................................

NGC "C4" CONNECTOR TERMINAL I.D.............................................................................................................

SOLENOID PACK UPDATE TSB.....................................................................................,......................................

4

5 11 13 14 18 20 22 30 31 32

42 44 50 53 54 56 65 73 83 89 91 96 96 97 98

108 109 112 113 114 115 116

CAUTION: ATSG service manuals are intended for use by professional, qualified technicians. Attempting repairs or service without the proper training, tools and equipment could cause injury to you or others and damage to the vehicle that may cause it not to operate properly.

AUTOMATIC TRANSMISSION SERVICE GROUP

18635 S.W. 107 AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

2

Technical Service Information

45/545RFE TRANSMISSION

FOUND BEHIND 4.7L ENGINE FOR 1999

IN 3.7 LIBERTY AND 5.7 DODGE TRUCKS

4 = Four Forward Speeds

5 = Five Forward Speeds

5/45 = Relative Torque Capacity

R = Rear Wheel Drive

FE = Fully Electronic

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP

3

SELECTOR

POSITION

PARK ON

REVERSE

NEUTRAL

OD-1ST

OD-2ND

2ND PRIME

OD-3RD OD-4TH

OD-5TH**

OD-LIMP

Technical Service Information

45/545RFE CLUTCH APPLICATION CHART

LO/REV

CLUTCHUDCLUTCH

ON ON 3.00:1 ON ON

*

ON ON ON ON ON ON

ON

SECOND CLUTCHODCLUTCH

ON

ON ON

FOURTH CLUTCH

ON

REVERSE

CLUTCH

LOW OVERRUN

CLUTCH

HOLD

GEAR

RATIO

3.00:1

1.67:1

1.50:1

1.00:1

0.75:1

0.67:1

1.00:1

(2)-1ST

(2)-2ND

(2)-LIMP

(1)-1ST

L/R Clutch is on only with the output shaft speed below 150 RPM.

*

545RFE Only

**

ON

*

ON

*

Underdrive

Clutch

ON ON ON

ON

ON ON

Overdrive

Clutch

Reverse

Clutch

Fourth

Clutch

Second

Clutch

HOLD

Low/Reverse

Clutch

3.00:1

1.67:1

3.00:1

Low Roller

Clutch

Figure 2

4

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

MECHANICAL OPERATION

The operation of the 45RFE is very similar to the Chrysler 41TE (A604) and 42LE (A606) transaxles that you are already familiar with. The 45/545RFE has no internal bands, but uses several different clutch assemblies instead. The Input Clutch Housing retains the underdrive clutch, overdrive clutch and the reverse clutch and is set up almost identical to the 41TE transaxle, except much larger. The 45/545RFE also contains seperate holding clutches, such as the 2nd clutch, 4th clutch and the low/reverse clutch. This unit also uses one overrunning or freewheel device called the low overrun clutch. To achieve its different gear ratios, the 45/545RFE applies different combinations of two clutch packs at a time, as shown in Figure 2. In Park and Neutral, only the low/reverse clutch is applied. Notice also that a unique characteristic of the 45/545RFE is its alternate 2nd gear ratio, or "2nd prime" as it is known. The 2nd prime is enabled only during kickdown shifts above certain speeds, that enhances vehicle performance by allowing for a higher gear ratio passing gear at highway speeds. Refer to the chart in Figure 2 for the clutches that are applied for each shift lever position. Another feature of this unit is the three planetary gear sets, as shown in Figure 2, which is one more than you are used to seeing in a Chrysler unit. These planetary gear sets provide a deeper 1st and reverse ratio and does not need a seperate overdrive unit. All gear ratios are also shown in the chart in Figure 2.

SELECTOR

POSITION

P/N

Under 8

P/N

Over 8

REVERSE

REV-Block

OD-1ST

OD-2ND

2ND PRIME

OD-3RD

OD-4TH

OD-5TH

(1)-1ST Or

Autostick

FAILSAFE

SOLENOID CHART

N.V. N.V. N.V. N.V.N.A. N.A.

LR/CC

SOLENOIDUDSOLENOIDODSOLENOID

ON

* * * *

ON

OFF OFF OFF OFF OFF OFF OFF

ON

2nd CLUT

SOLENOID

ON

4th CLUT

SOLENOID

ON

Multi-Select SOLENOID

OFF

ON

Variable Force

SOLENOID

Modulating

Modulating (EMCC) if the Converter Clutch has been signaled.

*

N.V.= Normally Vented N.A.= Normally Applied

Figure 3

AUTOMATIC TRANSMISSION SERVICE GROUP

5

Technical Service Information

ELECTRICAL OPERATION

The Transmission Control Module (TCM) or New Generation Controller (NGC) controls all of the transmission functions and is located in the engine compartment, as shown in Figure 5. The Powertrain Control Module (PCM) does not control the transmission, other than models that have the NGC, as the Transmission control is combined with the PCM. The electronic components of the 45/545RFE transmission consist of various sensors and switches as input information to the TCM, that the TCM uses to determine the appropriate gear ratio and shift schedule points. There is also the associated wiring, fuses, relays, connectors, splices and grounds for the transmission to function as designed. A complete transmission wiring schematic has been provided for you in Figure 9. The final output from the TCM is to the six shift solenoids and the line pressure control solenoid located in the Solenoid Pack/Transmission Range Sensor assembly and bolted on the valve body as shown in Figure 4. The solenoids in this transmission are unique in that some are normally vented and some are normally applied and is illustrated in Figure 4. The TCM also communicates with other control modules, such as the PCM, currently using the two wire CCD Bus for communication. NGC modules use PCI or CAN bus . The TCM receives power from two sources, fused battery power to pin 56 and fused ignition switch input to pin 11, both at the 60-way connector on the TCM. The TCM also has a ground to complete its electrical circuit. (See Figure 8). See the NGC schematic on Page 113.

INPUTS TO THE TCM

Input and Output Shaft Speed Sensors - are located on the left side of the transmission and are illustrated in Figure 11. The input shaft speed sensor reads input shaft speed off of a tone wheel. The TCM/NGC compares this reading with that of the output shaft speed sensor, which is also read off of a tone wheel. This comparison provides the TCM/NGC with gear ratio information. The crankshaft position sensor supplies the TCM with engine RPM data that is also critical to scheduling shift points.

Line Pressure Sensor - is located on the right rear of the transmission, as illustrated in Figure 11, and supplies the TCM/NGC with line pressure information. The line pressure sensor operates much like a throttle position sensor.

Transmission Fluid Temperature Sensor - is located in the Solenoid Pack/Transmission Range Sensor and is a thermister that the TCM uses to moniter transmission fluid temperature.

Solenoid Pack/Transmission Range Sensor - contains several different inputs to the TCM/NGC. The TRS contains five switches that tell the TCM/NGC, through different combinations of switch states, what position the manual gear selector has been placed. There is also a back-up lamp switch incorporated in the TRS. In addition to the switches above, there are five pressure switches to monitor pressure in the Low/Rev, Second Clutch, Fourth Clutch, Underdrive Clutch and Overdrive Clutch hydraulic circuits. The primary function of these switches is to help the TCM/NGC detect when clutch circuit hydraulic failures occur. The TCM/NGC continuously monitors the switches for the correct states (Open or Closed) in each gear as shown in the chart in Figure 5.

6

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

ADAPTIVE LEARNING

The 45/545RFE transmission uses an "Adaptive Learning" feature which allows the TCM/NGC to modify the clutch apply rate to maintain consistant shift quality. This is done based on the amount of wear on the friction elements. The TCM/NGC then adjusts the duty cycle of the shift solenoids to achieve the smoothest possible upshifts and downshifts. The TCM/NGC adjusts the "Clutch Volume Index" when a shift change takes place to optimize clutch to clutch timing. Clutch Volume Index is described in Figure 6, along with proper clutch volumes and clutch clearances for the 45/545RFE transmission.

OUTPUTS FROM THE TCM

Transmission Control Relay - located in the Power Distribution Center (PDC), as shown in Figure 10, and recieves a ground signal from terminal 15 at the TCM/NGC to close the relay. Refer to the wiring schematic in Figure 9.

Underdrive Solenoid with Pressure Switch - This solenoid is normally applied and controls oil to the UD clutch in all 1st, 2nd, 2nd Prime and 3rd gears of the transmission.

Overdrive Solenoid with Pressure Switch - This solenoid is normally vented and controls oil to the OD clutch in 3rd and 4th gears in the transmission.

Fourth Clutch Solenoid with Pressure Switch - This solenoid is normally vented and controls oil to the 4th clutch in all 4th and 2nd Prime gears in the transmission.

Second Clutch Solenoid with Pressure Switch - This solenoid is normally vented and controls oil to the 2nd clutch in all 2nd gears and Fifth (545RFE) in the transmission.

Low/Reverse Solenoid with Pressure Switch - This solenoid is normally vented and is used to apply the L/R clutch in 1st from neutral, or coast down to 1st, and to control oil for converter clutch engagement.

Multi-Select Solenoid - The Multi-Select Solenoid is normally applied and controls the OD clutch in 3rd gear Limp-in, 2nd clutch in Manual 2, 2nd Limp-in and the Low/Reverse clutch in reverse.

LIMP-IN MODE OPERATION

The TCM/NGC has the ability to monitor all transmission related electrical components and if it detects a problem, takes appropriate action, and most of the time results in the TCM/NGC setting a Diagnostic Trouble Code (DTC). Whether this results in MIL illumination, or Limp-in Mode operation, depends on the type of DTC that was set. If the TCM/NGC determines that transmission damage may result from the DTC type that was set, the TCM/NGC will shut off the ground signal to the transmission control relay which will shut off all power to the transmission and the vehicle will be in Limp-in Mode Operation. When in Limp-in Mode Operation, with the shift lever in the "Drive" position the transmission will be in 3rd gear, and if the shift lever is moved to "2" or "L" position the transmission will be in 2nd gear. This will allow the driver to manually shift the transmission to Limp home.

DIAGNOSIS AND SERVICE INFORMATION

You have been provided with the 23-way case connector pin cavity identification and pin function in Figure 7, and 60-way TCM or NGC connector pin cavity identification and pin function in Figure 8 and page115 for NGC. A complete transmission wiring schematic is provided in Figure 9 , on page 113 for NGC. Transmission control relay location in the power distribution center is shown in Figure 10. Special tools that might be needed are illustrated in Figure 12, along with the identification of the pressure taps that are available on the main valve body. Air pressure test passage identification is provided for you in Figure

13.

AUTOMATIC TRANSMISSION SERVICE GROUP

7

Technical Service Information

TRANSMISSION

RANGE SENSOR

L/R Clutch

Seal

97

4799591

23-WAY

CONNECTOR

SOLENOID

PACK

PRESSURE

CONTROL

SOLENOID

2nd Clutch

TWO DIFFERENT TYPES OF SHIFT SOLENOIDS

Underdrive Solenoid

Multi-Select Solenoid

Seal

VALVE BODY

4th Clutch

Seal

Overdrive Solenoid

4th Clutch Solenoid

2nd Clutch Solenoid

Low/Reverse Solenoid

"Solenoid Off"

"Normally Applied"

"Solenoid Off"

"Normally Vented"

Figure 4

8

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

PRESSURE SWITCHES

The pressure switches are located inside the solenoid and pressure switch assembly and are only serviced by replacing the complete assembly. The Transmission Control Module and or New Generation Control module is located as shown below and relies on five pressure switches to monitor pressure in the Low/Rev, 2nd Clutch, 4th Clutch, Underdrive, and Overdrive hydraulic circuits. The primary function of these switches is to help the TCM/NGC detect when the clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and indicate whether or not pressure exists. The switches are continuously monitored by the TCM/NGC for the correct states (Open or Closed) in each gear as shown in the chart below.

SWITCH CHART

Low/Rev

2nd Clut 4th Clut Underdrive Overdrive

Park/Neut

Reverse

First

Second

2nd Prime

Third

Fourth

**Fifth

* L/R is closed if output speed is below 150 RPM in Drive and Manual 2. L/R is open in Manual 1. **545RFE

TRANSMISSION

CONTROL MODULE

JEEP

Closed

Open

Closed*

Open

Open Open

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed Closed

Open

Closed

ClosedOpen OpenOpen Closed

NGC MODULE

IS LOCATED NEAR

FIREWALL AND

HAS 4 CONNECTORS

TRANSMISSION

CONTROL MODULE

CAN BE FOUND ON

THE RADIATOR SUPPORT

ON DODGE TRUCKS

FRONT

Figure 5

AUTOMATIC TRANSMISSION SERVICE GROUP

60 WAY

CONNECTOR

9

Technical Service Information

CLUTCH VOLUME INDEXES

An important function of the TCM/NGC is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack properly. The TCM/NGC monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input Speed Sensor sends an AC voltage signal to the TCM/NGC that represents input shaft rpm. The Output Speed Sensor provides the TCM/NGC with output shaft speed information. By comparing these two inputs, the TCM/NGC can determine actual gear ratio. This is important to the CVI calculation because the TCM/NGC determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is turning at 1000 rpm and the output shaft is turning at 500 rpm, the TCM/NGC can determine that the gear ratio is 2:1. In 3rd gear the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for a gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for the adaptive controls. As friction material wears, the volume of fluid needed to apply the friction element increases. Certain mechanical problems within the transmission assembly such as broken return springs, out of position snap rings, excessive clutch pack clearance, or improper assembly can cause inadequate or out-of-range CVI readings. Also defective Input/Output Speed Sensors, wiring and poor connections may cause these same conditions. The following chart identifies the proper CVIs, when they are monitored and updated and the proper clutch pack clearances.

CLUTCH VOLUMES AND CLEARANCES

CLUTCH WHEN UPDATED PROPER VOLUME CLUTCH CLEARANCE

Low/Reverse

2nd Clutch

Overdrive

4th Clutch

Underdrive

Reverse

2-1 or 3-1 Downshift 82 to 134 1.14-1.91mm (.045"-.075")

3-2 Kickdown shift

2-3 Upshift

3-4 Upshift

4-3 Kickdown shift

Not Monitored Not Monitored

Figure 6

25 to 64

30 to 64

44 to 92

0.53-1.27mm (.021"-.050")

1.01-1.65mm (.040"-.065")

0.81-1.35mm (.032"-.053")

0.76-1.60mm (.030"-.063")

0.81-1.24mm (.032"-.049")

10

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

23-WAY CASE CONNECTOR PIN CAVITY IDENTIFICATION AND FUNCTION

212223

17

123

4

567

89101112

13

141516

17181920

"Front"

20

16

12

212223

81

19

15

11

7

14

13

8

9

01

5

6

2

3

4

1

Vehicle Harness Connector

CAVITY

1

2

3

4

5

6

7

8

9

10

11

12

13

WIRE

COLOR

White/Tan

Lt. Green

Brown/Yellow

White

Violet/White

Violet/Black

Brown

Violet

Lt. Green/Black

Red

Dk. Blue

Yellow/Dk. Blue

Tan/Black

Transmission

Case Connector

FUNCTION

Fused Ignition Switch Battery Voltage

LR/TC Clutch Solenoid Control

Park/Neutral Position Switch Signal

Transmission Range Sensor (T41) Signal

Transmission Range Sensor (T42) Signal

Back-Up Lamp Feed

Overdrive Clutch Solenoid Control

Transmission Range Sensor (T3) Signal

Transmission Range Sensor (T1) Signal

Transmission Control Relay Output

4th Clutch Pressure Switch Signal

Line Pressure Control Solenoid Control

Transmission Range Sensor (T2) Signal

14

15

16

17

18

19

20

21

22

23

Brown/Lt. Blue

Lt. Blue

Orange/Black

Pink

Gray

Dk. Green/White

White/Dk. Blue

Violet/Lt. Green

Dk. Blue/Black

Violet

AUTOMATIC TRANSMISSION SERVICE GROUP

Low/Reverse Clutch Pressure Switch Signal

2nd Clutch Pressure Switch Signal

Overdrive Clutch Pressure Switch Signal

Underdrive Clutch Solenoid Control

Underdrive Clutch Pressure Switch Signal

4th Clutch Solenoid Control

2nd Clutch Solenoid Control

Multi-Select Solenoid Control

Speed Sensor Ground

Transmission Oil Temperature Sensor Signal

Figure 7

11

Technical Service Information

60-WAY CONNECTOR PIN CAVITY IDENTIFICATION AND FUNCTION

CAVITY

1 2 3 6

21

41

42

43

44

45

46

47

48

49

50

1

22

2

23

3

24

4

25

5

26

6

27

7

28

8

29

9

30

10

7 8

9 10 11 12 13 14 15 16 17 18 19 20 28 29

51

52

53

54

55

56

57

58

59

60

11

31

12

32

13

33

14

34

15

35

16

36

17

37

18

38

19

39

20

40

30 36 37 38 39 40 41 42 43 46 47 48 49 50 51 52 53 54 55 56 57 59 60

WIRE

COLOR

Lt. Green/Black

Tan/Black

Violet

Gray/Black

Pink

Red

Orange/Black Yellow/Dk.Green Orange/Dk. Blue

Brown

Dk. Blue/Black

Lt. Green/White

Pink/Yellow

Red Red

Yellow/Dk. Blue

White/Dk. Blue

Lt. Green

White/Orange

Gray

Violet/Tan

Red Black/Yellow Gray/Lt. Blue Black/Yellow

Violet/Lt. Green

White

Violet/White

Yellow/Violet

Lt. Green

Lt. Blue

Dk. Blue

Violet/White

Brown/Lt. Blue

Black/Lt. Blue

Red/Black Black/Red

Violet

Pink

Red/White

Black/Yellow

Dk. Green/White

Brown

FUNCTION

Transmission Range Sensor T1 Signal Back-up Lamp Relay Control Transmission Range Sensor T3 Signal Crankshaft Position Sensor Signal SCI Transmit Fused Ignition Switch Output (Start) Overdrive Clutch Pressure Switch Signal Torque Management Request Fused Ignition Switch Output (Start-Run) Overdrive Clutch Solenoid Control Speed Sensor Ground Output Speed Sensor Signal Transmission Control Relay Control Transmission Control Relay Output Transmission Control Relay Output Line Pressure Control Solenoid Control 2nd Clutch Solenoid Control L/R-TCC Clutch Solenoid Control Vehicle Speed Sensor Signal Underdrive Clutch Pressure Switch Signal Line Pressure Sensor Signal Transmission Control Relay Output Ground 5 Volt Supply Ground Multi-Select Solenoid Control Transmission Range Sensor (T41) Signal Transmission Range Sensor (T42) Signal PCI Bus SCI Recieve 2nd Clutch Pressure Switch Signal 4th Clutch Pressure Switch Signal Overdrive Off Switch Signal Low/Reverse Clutch Pressure Switch Signal Sensor Ground Input Speed Sensor Signal Ground Transmission Oil Temperature Sensor Signal Underdrive Clutch Solenoid Control Fused Battery Voltage Ground 4th Clutch Solenoid Control Overdrive Clutch Solenoid Control

12

NGC Information is located on Page 115

Figure 8

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

POWER DISTRIBUTION CENTER

FUSE 5

30A

40 55 60 19 59 205318 3929 3748 5747 50 3 2 1 41 42 549

TRANSMISSION

CONTROL RELAY

16 15 53 38 301736

10 1217 721 23 2220 19 18 16 15 14 138 9 4 3 5 1 6112

NGC Schematic

located on Page 113

Pressure Sensor

Line

Pressure

Ground

5 Volt

Supply

Sensor Signal

TRANSMISSION CONTROL MODULE

Input Speed

Sensor

52 13 14

Output

Speed

Sensor

Back-up

Lamps

Starter

Relay

Ignition

Switch

12V

Back-Up

Lamp

Switch

Solenoid

Multi-Select

L/R

Pressure

Switch

Solenoid

Underdrive

2nd Clut Pressure

Switch

TRS

T42

Signal

Solenoid

Overdrive

Pressure

Switch

OD

TRS

T41

Signal

Solenoid

2nd Clutch

4th Clut

Pressure

Switch

TRS

T1

Signal

Solenoid

4th Clutch

LR/TCC

UD

Pressure

Switch

TRS

T2

Signal

Solenoid

Control

Pressure

Solenoid

TRS

T3

Signal

TFT

Sensor

Figure 9

AUTOMATIC TRANSMISSION SERVICE GROUP

13

Technical Service Information

TRANSMISSION CONTROL RELAY AND FUSE LOCATIONS EARLY MODELS

POWER DISTRIBUTION CENTER

AC

Clutch

Relay

Wiper

On/Off

Relay

Fuel Pump Relay

Spare Relay

Horn Relay

Wiper Hi/Lo Relay

Starter

Relay

Spare Relay

Automatic

Shutdown

Relay

Heater

Relay

Down-

Stream

Transmission

Control

Relay

Heater

Relay

Up-

Stream

14

Fuse 5

(30A)

Figure 10

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

INPUT SPEED

SENSOR

TITTJ243810187

P52119099AA 45RF

243810187P52119099AA

TO COOLER

099

AA

OUTPUT SPEED

SENSOR

LINE PRESSURE

SENSOR

LOCK-UP "ON"

FROM COOLER

PRESSURE

Figure 11

AUTOMATIC TRANSMISSION SERVICE GROUP

LOCK-UP "OFF"

PRESSURE

15

Technical Service Information

MANDATORY TOOLS NEEDED FOR CHECKING PRESSURES ON 45RFE

l

Pressure Tap Adapter Tool No. 8258, to check oil pressures through the valve body taps.

Line Pressure

Low/Reverse

Clutch Pressure

Line Pressure Adapter Tool No. 8259, to install into

the line pressure sensor circuit, and then reinstall the sensor and pressure gage.

VALVE BODY

Underdrive Clutch

Pressure

Reverse Clutch

Pressure

05111

1

AK

4799655

98

16

Overdrive Clutch

Pressure

4th Clutch

Pressure

Figure 12

AUTOMATIC TRANSMISSION SERVICE GROUP

2nd Clutch

Pressure

Technical Service Information

COOLER FILTER

BYPASS VALVE

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

COOLER FILTER

Low/Reverse

Clutch

2nd Clutch

AIR PRESSURE TESTS

4th Clutch

Overdrive

Clutch

Underdrive

Clutch

Reverse

Clutch

Figure 13

AUTOMATIC TRANSMISSION SERVICE GROUP

17

T41 T42

T3 T1 T2

Technical Service Information

TRS/SOLENOID BODY TESTS

3000 5%

TRANSMISSION RANGE SENSOR CHART

CIRCUIT METER P R N OD 2 1

T42-C2

T3-C3

T1-C4

T2-C5

T41 & GRD OR CONNECTOR PIN 4 & GRD

T42 & GRD OR CONNECTOR PIN 5 & GRD

T3 & GRD OR CONNECTOR PIN 8 & GRD

T1 & GRD OR CONNECTOR PIN 9 & GRD

T2 & GRD OR CONNECTOR PIN 13 & GRD

C

O O

C

CO O

C C

O

CCC

O O

O O O

O OT41-C1

OOO

C

C C

C = Closed O = Open

C

18

CONNECTOR PINS

LR/TCC 10 AND 2

OVERDRIVE

UNDERDRIVE

2ND CLUTCH

4TH CLUTCH

MULTI-SELECT

LINE PRESSURE

TOT SENSOR

AUTOMATIC TRANSMISSION SERVICE GROUP

SOLENOID RESISTANCE CHART

10 AND 7

10 AND 17

10 AND 20

10 AND 19

10 AND 21

10 AND 12

22 AND 23

Figure 14

RESISTANCESOLENOID

1.9 W @ 72°F

4.3 W @ 72°F

9.37k W @ 72°F

Technical Service Information

Meter shown checking T41 Circuit

and should correspond with chart in Figure 14. Solenoid tests must

be made thru case connector pins.

W

0.1

"Front"

2122

17

23

20

16

12

81

19

15

7

13

14

1011

8

9

4

5

6

3

1

2

W

mV

V

RPM

V

OFF

mA

A

mA

A

V

W

RPMCOMmAA

23-WAY

CONNECTOR

97

TRANSMISSION RANGE SENSOR

AND SOLENOID BODY ASSEMBLY

Transmission

Case Connector

4799591

Figure 15

AUTOMATIC TRANSMISSION SERVICE GROUP

19

OBDII

Codes

45RFE OBDII DIAGNOSTIC TROUBLE CODE LIST

Description

Technical Service Information

Limp-in MIL Illumination

P0120

P0600

P0705

P0715

P0720

P0725

P0731

P0732

P0733

P0734

P0736

P0740

P0750

Throttle Position Signal Out Of Range (29)

Bus Communication (19)

Internal TCM (17)P0604

Internal TCM (16)P0605

Malfunction Indicator Lamp Request P0700

Check Shifter Signal (28)

Input Speed Sensor Error (56)

Output Speed Sensor Error (57)

Engine Speed Sensor Circuit Error (18)

Gear Ratio Error In 1st Gear (51)

Gear Ratio Error In 2nd Gear (52)

Gear Ratio Error In 3rd Gear (53)

Gear Ratio Error In 4th Gear (54)

Gear Ratio Error In 4th Prime GearP0735

Gear Ratio Error In Reverse (50)

Torque Converter Clutch Control Circuit (38)

Low/Reverse Solenoid Circuit Error (C1)

2002 & UP

NO

YES YES

NO

YES

YES YES

YES

NO

YES

NO

YES

NO

YES

P0755

P0760

P0765

P0770

P0841

P0870

P0871

P0875

P0876

P0884

P0888

P0890

2nd Clutch Solenoid Circuit Error (C2)

Overdrive Solenoid Circuit Error (C3)

Underdrive Solenoid Circuit Error (C5)

4th Clutch Solenoid Circuit Error (C4)

L/R pressure Switch sense Circuit

2nd Clutch hydraulic pressure test FailureP0845

2nd Clutch Pressure Switch Sense CircuitP0846

Line Pressure FaultP0867

Line Pressure LowP0868

Line Pressure HighP0869

OD Clutch hydraulic pressure test Failure

OD Clutch Pressure Switch Sense Circuit

UD Clutch hydraulic pressure test Failure

UD Clutch Pressure Switch Sense Circuit

Power up at speed

Trans Control Relay output Always Off

Switched Battery Voltage Failure

NOTE: Letters or digits in parenthesis are for use with DRB scan tool. 545RFE DTC's are located on Page 112

2002 & UP

Figure 16

YES

YES YES

NO NO

YES YES

NO NO

YES YES

YES

20

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

45RFE OBDII DIAGNOSTIC TROUBLE CODE LIST

OBDII

Codes

P0891 P0932

P0944 P0987 P0988

P1720 P1721 P1722

P1724

P1726

P1727

P1728

P1732

P1733 P1734 P1735

P1736 P1737

P1738

P1739

P1765

P1767 P1768 P1770 P1771

P1772

P1773

P1775

P1776

P1781

P1784

P1787 P1790

P1792 P1793

P1794

P1799

P2700

P2701 Inadequate Element Volume 2nd Clutch P2702 Inadequate Element Volume Overdrive Clutch

P2703 Inadequate Element Volume Underdrive Clutch

P2704 Inadequate Element Volume 4th Clutch

P2706 Multi-Select Solenoid Circuit Fault

Description

Transmission Control Relay always ON Line Pressure Sensor Fault Loss of Prime 4th Clutch Hydraulic Pressure Test Failure 4th Clutch Pressure Switch Sense Circuit Battery was DisconnectedP1684 Bus communication with Engine Control Module faultP1694

Restricted Port in T3 (65)P1715

Line Pressure Out Of Range (C8) Line Pressure Sensor Voltage Out Of Range (CA)

Line Pressure Low (C9)

Line Pressure High (CB)

Overdrive Pressure Switch Did Not Close (BO)

Underdrive Pressure Switch Did Not Close (A8)

2nd Clutch Pressure Switch Did Not Close (A2)

Overdrive Pressure Switch Circuit Error (90)

Underdrive Pressure Switch Circuit Error (88) 2nd Clutch Pressure Switch Circuit Error (82) Inadequate Element Volume 4th Clutch (64) Gear ratio in 2nd Prime (55) Multi-Select Solenoid Circuit Error (C6) High Temperature Operation Activated (Info Only) (75)

Power-Up At Speed (76)

Switched Battery Voltage Failure (80)

Transmission Control Relay Always ON (14) Transmission Control Relay Always OFF (15) Inadequate Element Volume L/R (60) Inadequate Element Volume 2nd Clutch (61)

Inadequate Element Volume OD Clutch (62)

Inadequate Element Volume UD Clutch (63)

Solenoid Switch Valve Stuck In TCC Position (37)

Solenoid Switch Valve Stuck In L/R Position (47)

OD Pressure Switch Circuit Error (84)

Low/Reverse Pressure Switch Circuit Error (81)

OD Hydraulic pressure switch Failure (A4)

Fault Immediately After Shift (36) Battery Was Disconnected (12) Torque Management Request (TRD) Sense Circuit (48)

Speed Sensor Ground Error (58)

Calculated Oil Temperature In Use (74)

Inadequate Element Volume Low Reverse Clutch

2002 & UP

NOTE: Letters or digits in parenthesis are for use with DRB scan tool

2002 & UP

AUTOMATIC TRANSMISSION SERVICE GROUP

2002 & UP

Figure 17

2002 & UP

Limp-in MIL Illumination

YES

YES YES YES YES

NO NO

NO

YES YES

YES

YES YES

NO YES YES YES YES

NO

YES YES YES

NO

YES

YES YES

NO

NO YES

NO

NO NO

YES YES

YES

YES YES YES

YES

NO NO

NO

YES YES

YES

NO

NO NO

YES

NO

YES

YES YES

NO

YES

NO

21

Technical Service Information

45/545RFE TRANSFER PLATE

Reverse Clutch

Pressure

2nd Clutch

Pressure

Underdrive Clutch

Pressure

4th Clutch

Pressure

98

4799655

05111

TRANSFER PLATE

AK

1

Overdrive Clutch

Pressure

Low/Reverse Clutch

Pressure

Line Pressure

22

Figure 18

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

45/545RFE VALVE BODY SPACER PLATE

Figure 19

AUTOMATIC TRANSMISSION SERVICE GROUP

23

Technical Service Information

45/545RFE ACCUMULATOR AND CHECKBALL LOCATIONS

SEVEN CHECKBALL LOCATIONS

ARE SHOWN BELOW

OD

ACCUM

UD

ACCUM

4TH CLUT

ACCUM

2ND CLUT

ACCUM

Figure 19

LOW/REV

ACCUM

24

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

45/545RFE OIL PUMP BODY AND GEARS

2

Shuttle Valve

A dual stage oil pump is also new for the 45RFE. The pump has three gears, one drive gear and two driven gears as shown above. Both stages of the pump supply fluid during idle and at low engine speeds. Under these conditions there is not enough pressure from the primary stage to close the shuttle valve. As engine speed increases, so does the output from the primary stage. Once the pressure from the primary stage builds up, the shuttle valve is forced closed and in this condition the secondary stage has no effect and the primary side supplies all of the pressure needed for proper transmission operation. Note: early casting shown.

3

Figure 20

AUTOMATIC TRANSMISSION SERVICE GROUP

25

Technical Service Information

45/545RFE PUMP SPACER PLATE

26

Early plate shown

Figure 21

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Torque Converter Clutch

Accumulator Valve

Torque Converter Clutch

Control Valve

Torque Converter Clutch

Limit Valve

VALVE LINE-UP IDENTIFICATION AND

LOCATIONS IN PUMP COVER

Torque Converter Clutch

Switch Valve

Pressure Regulator Valve

Early pump shown

Figure 22

AUTOMATIC TRANSMISSION SERVICE GROUP

PUMP COVER

27

Exhaust

Technical Service Information

45/545RFE OIL PUMP COVER PASSAGE

AND FEED HOLE IDENTIFICATION

Converter

Release

Lube

Reverse

Clutch

Underdrive

Clutch

Overdrive

Clutch

4799578

Early pump shown

28

Figure 23

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

45/545RFE OIL PUMP STATOR PASSAGE

AND FEED HOLE IDENTIFICATION

Overdrive

Clutch

Underdrive

Clutch

Reverse Clutch

Bleed Orifice

Overdrive Clutch

Bleed Orifice

Lube

Converter

Release

Reverse

Clutch

Exhaust

Overdrive

Clutch

Underdrive

Clutch

Figure 24

AUTOMATIC TRANSMISSION SERVICE GROUP

Reverse

Clutch

29

Technical Service Information

OIL PRESSURE TESTS

Line Pressure Adapter Tool No. 8259, to install into the line pressure sensor circuit, and then reinstall the sensor and pressure gage.

Tool No.8259

Line Pressure

Sensor

l

LOCK-UP "OFF"

PRESSURE

LOCK-UP "ON"

PRESSURE

l

PRESSURE CHART

GEAR

PARK

LINE

35-165 35-118

TCC ON TCC OFF

15-80

30

MAIN LINE

PRESSURE

REVERSE

NEUTRAL

OD-1ST

TCC OFF

TCC ON

45-250

35-165

Figure 25

AUTOMATIC TRANSMISSION SERVICE GROUP

15-80

35-80

40-11840-75

35-118

0