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

Technical Service Information

(1) Transmission fluid level must be checked before performing the pressure tests and must be at normal operating temperature for accurate check. Drive vehicle if necessary to bring fluid temperature up to normal operating temperature of 82°C (180°F). (2) Position vehicle on flat level surface. (3) Start and run engine at curb idle speed. (4) Apply Parking Brakes. (5) Shift transmission through all gear ranges and then back to the Neutral position. (6) Remove dipstick and check fluid level. (A) Correct level is in crosshatch area. (B) Correct maximum level is to MAX arrow. (C) Incorrect level is at or below MIN line. (7) If fluid level is low, add only enough of the Mopar® ATF Plus 3 or 4, Type 7176 to restore correct fluid level. Do not overfill (See Figure 26).

Dexron II fluid is NOT recommended. Clutch chatter can result from the use of improper fluid.

PRESSURE TEST LOCATIONS AND PROCEDURE

There are only two pressure taps supplied on the transmission case. The torque converter ON and torque converter OFF taps are located on the right side of the transmission case, shown in Figure 25. There are two available methods to determine main line pressure. The DRB Scan Tool can be used to read main line pressure from the line pressure sensor. The 2nd method is to install Line Pressure Adapter 8259 into the transmission case, and re-install the line pressure sensor and the pressure gauge into the adapter, shown in Figure 25. This will allow a comparison of the DRB readings and the pressure gauge to determine the accuracy of the feedback to the controller. Refer to the chart in Figure 25 for proper pressure readings. To access any of the other pressure tap locations, the transmission oil pan must be removed, the pressure taps removed from the valve body and the Valve Body Pressure Tap Adapter 8258 installed. Refer to Figure 12 on Page 16. The extensions supplied with Adapter 8258 will allow the installation of pressure gauges to the valve body to test individual clutch pack pressures. Refer to Figure 12 on Page 16 for pressure tap identification.

GENERAL OPERATION INFORMATIONFLUID LEVEL CHECK PROCEDURE

The 45/545RFE transmission is a sophisticated, multi-range, electronically controlled transmission which combines optimized gear ratios for very responsive performance and state of the art efficiency. Features include driver adaptive shifting and three planetary gear sets to provide wide ratio capability with precise ratio steps to optimize driveability. The three planetary gear sets also make available a unique alternate 2nd gear ratio. The primary 2nd gear ratio falls between 1st and 3rd gears for normal upshifts on acceleration. The alternate 2nd gear ratio (2nd Prime) allows for a smoother 4-2 kickdown at high speeds to provide 2nd gear passing performance over a wider hi-way crusing range. The 45/545RFE offers full electronic control of all automatic up and downshifts, and features real-time adaptive closed-loop shift and pressure control. Electronic shift and converter clutch controls help protect the transmission from damage due to high temperatures, which can occur under severe operating conditions. The 45/545RFE also features a unique dual stage oil pump with electronic output pressure control. Under most driving conditions, pump output pressure greatly exceeds that which is needed to keep the clutches applied. The 45/545RFE pump pressure control system monitors input torque and adjusts the pump pressure accordingly. The primary stage of the pump works continuously. The second stage is bypassed when demand is low. The control system also monitors input and output speed and, if clutch slippage is observed, the pressure control solenoid duty cycle is varied, increasing pressure in proportion to demand.

PRIMARY MECHANICAL COMPONENTS

3 MULTIPLE DISC INPUT CLUTCHES 3 MULTIPLE DISC HOLDING CLUTCHES 3 PLANETARY GEAR SETS 5 HYDRAULIC ACCUMULATORS DUAL STAGE HYDRAULIC OIL PUMP VALVE BODY TRANSMISSION RANGE SENSOR/SOLENOID PACK

AUTOMATIC TRANSMISSION SERVICE GROUP

31

OK MAXMIN

ACCEPTABLE

FLUID LEVEL

Technical Service Information

TYPICAL

DIPSTICK

MAXIMUM CORRECT

FLUID LEVEL

Figure 26

"O" RING

TRANSMISSION DISASSEMBLY

1. Drain fluid from the transmission.

2. Clean exterior of the transmission thoroughly with a suitable solvent or pressure washer.

3. Remove the torque converter from the trans mission, remove and discard the "O" ring from the converter hub (See Figure 27).

4. Remove the manual shift lever.

5. Remove both input and output speed sensors from the case, as shown in Figure 28, remove and discard both "O" rings.

6. Remove the line pressure sensor from the case, as shown in Figure 29, remove and discard the "O" rings.

7. Remove the 12 extension housing to case retaining bolts using a 15mm socket and then remove extension housing (See Figure 30).

8. Remove the park gear snap ring from output shaft and remove park gear (See Figure 30).

9. Using a dial indicator, measure and record the output shaft end-play reading.

10. Using a dial indicator, measure and record the input shaft end-play reading.

TITTJ243810187

P52119099AA 45RF

243810187P52119099AA

NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft is pushed inward and the indicator zeroed, the first stop felt when the input shaft is pulled outward is the movement of the input shaft in the input clutch hub. This value should not be included in the end-play measurement and therefore must be recorded and subtracted from the total dial indicator reading.

Figure 27

099

AA

32

Figure 28 Figure 29

AUTOMATIC TRANSMISSION SERVICE GROUP

TITTJ243810187

P52119099AA 45RF

243810187P52119099AA

Technical Service Information

PARK GEAR

099

AA

PARK GEAR SNAP RING

Figure 30

10. Remove the 15 bottom pan bolts, using an 8mm socket, as shown in Figure 31.

11. Remove bottom oil pan as shown in Figure 31.

NOTE: This unit uses no gaskets anywhere. The extension housing and bottom pan are sealed with RTV.

12. Remove the bottom pan filter retaining screw, using a 25 Torx bit (See Figure 32).

13. Remove and discard the bottom pan oil filter, as shown in Figure 32.

Continued on next Page.

05111

4799655

1

AK

98

05111

4799655

1

AK

98

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

Figure 31 Figure 32

AUTOMATIC TRANSMISSION SERVICE GROUP

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

33

VALVE BODY

RETAINING BOLTS

Technical Service Information

05111

4799655

1

AK

98

VALVE BODY

RETAINING BOLTS

VALVE BODY

RETAINING BOLTS

Figure 33

COOLER FILTER

BYPASS VALVE

05111

4799655

1

AK

98

COOLER FILTER

34

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

Figure 34 Figure 35

AUTOMATIC TRANSMISSION SERVICE GROUP

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

Technical Service Information

14. Remove the six valve body retaining bolts that are illustrated in Figure 33, using 8mm socket.

15. Remove the complete valve body and the TRS/Solenoid body as an assembly as shown in Figure 34, and set aside for component disassembly.

16. Remove and discard the cooler oil filter from the transmission case as shown in Figure 35.

17. Remove the cooler by-pass valve from case, as shown in Figure 35.

18. Remove the outer snap ring retaining the trans mission front cover in the transmission case as shown in Figure 36.

19. Remove the inner snap ring retaining the front cover to the oil pump as shown in Figure 36.

20. Reach through one of the case openings in the valve body area with a long blunted tool, and tap the transmission front cover from the case. Refer to Figure 36.

21. Remove the six bolts retaining the oil pump in the transmission case (See Figure 36).

22. Remove the oil pump from the transmission. Hold down on the input shaft to prevent the input clutch housing assembly from coming out with the oil pump (See Figure 36.

23. Set the oil pump assembly aside for component disassembly. Note: Early pump illustrated.

The 07 and up pump does not house the front seal and does not require the #5 snap ring.

5

4

3

2

4

6

1

7

9

1 9

2 3 3

8 5

C R

-

2

A

2

1

0

2

Continued on next Page.

2

1

1. COMPLETE PUMP ASSEMBLY.

2. PUMP TO CASE RETAINING BOLTS (6 REQUIRED).

3. PUMP COVER PLATE (MOLDED SEALS).

4. PUMP COVER PLATE OUTER RETAINING SNAP RING.

5. PUMP COVER PLATE INNER RETAINING SNAP RING.

Figure 36

AUTOMATIC TRANSMISSION SERVICE GROUP

35

Technical Service Information

NUMBER ONE

THRUST BEARING

INPUT CLUTCH

HOUSING ASSEMBLY

24. Remove the input clutch housing assembly by lifting straight up as shown in Figure 37.

25. Remove the number one thrust bearing from inside the input housing as shown in Figure 37.

26. Remove the number 5 selective thrust bearing from back side of the input housing, or from the 2-4 support in transmission (See Figure 37).

27. Set the input clutch housing assembly aside for component disassembly.

28. Remove the 2-4 clutch retainer front snap ring, which is a tapered snap ring, from transmission case as shown in Figure 38.

29. Remove the 2-4 clutch retainer from the trans mission case, as shown in Figure 38, and set aside for component disassembly.

30. Remove the 2-4 clutch retainer rear snap ring, which is a flat snap ring, from the transmission case as shown in Figure 38.

31. Remove the 2nd clutch pack, 2 steel plates and 2 friction plates, from the transmission case as shown in Figure 39.

32. Remove the 2nd clutch pressure plate from the transmission case as shown in Figure 39.

NUMBER FIVE

THRUST BEARING

(SELECTIVE)

Continued on Page 38.

36

Figure 37

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

1

2

3

4

2

5

1. 2-4 CLUTCH RETAINER TAPERED SNAP RING (GOES IN CASE).

2. NUMBER 5 THRUST BEARING (SELECTIVE).

3. 2-4 CLUTCH RETAINER.

4. 2-4 CLUTCH RETAINER FLAT SNAP RING (GOES IN CASE).

Figure 38

AUTOMATIC TRANSMISSION SERVICE GROUP

5

1. SECOND CLUTCH STEEL PLATES (2 REQUIRED).

2. SECOND CLUTCH FRICTION PLATES (2 REQUIRED).

3. SECOND CLUTCH BACKING PLATE.

4. NUMBER SIX THRUST BEARING.

Figure 39

37

Technical Service Information

33. Remove the number 6 thrust bearing if it is present. It may have been stuck to the 2-4

1

2

3

4

retainer (See Figure 40).

34. Remove the rear selective plate as shown in Figure 40.

35. Remove reaction internal ring gear assembly as shown in Figure 40.

36. Remove the number 7 thrust bearing as shown in Figure 40.

37. Remove the reaction sun gear as shown in Figure 40.

38. Remove the number 8 thrust bearing as shown in Figure 40.

39. Remove the reaction carrier/reverse sun gear assembly as shown in Figure 41.

40. Remove the number 9 thrust bearing as shown in Figure 41.

5

1

6

2

1. NUMBER 6 THRUST BEARING.

2. REAR SELECTIVE THRUST PLATE.

3. REACTION INTERNAL RING GEAR ASSEMBLY.

4. NUMBER 7 THRUST BEARING.

5. REACTION SUN GEAR.

6. NUMBER 8 THRUST BEARING.

Figure 40 Figure 41

38

1. REACTION CARRIER/REVERSE SUN GEAR ASSEMBLY.

2. NUMBER 9 THRUST BEARING.

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

41. Remove reverse carrier/input ring gear "flat" snap ring from the input internal ring gear as shown in Figure 42.

42. Remove the reverse carrier/input ring gear assembly as shown in Figure 42.

43. Remove the number 10 thrust bearing assembly as shown in Figure 42.

44. Remove the input sun gear assembly as shown in Figure 43.

45. Remove the number 11 thrust bearing as shown in Figure 43.

46. Remove the input planetary carrier/reverse internal ring gear as shown in Figure 43.

Continued on Page 40.

1

2

3

2

3

1. REVERSE CARRIER/INPUT RING GEAR "FLAT" SNAP RING.

2. REVERSE PLANETARY CARRIER ASSEMBLY.

3. NUMBER 10 THRUST BEARING.

Figure 42

AUTOMATIC TRANSMISSION SERVICE GROUP

1. INPUT SUN GEAR ASSEMBLY.

2. INPUT CARRIER/REVERSE INTERNAL RING GEAR ASSEMBLY.

3. NUMBER 11 THRUST BEARING.

Figure 43

39

Technical Service Information

47. Remove the input internal ring gear assembly from the transmission case (See Figure 44).

48. Remove the number 12 thrust bearing from the low/reverse clutch housing assembly as shown in Figure 44.

49. Remove the "Tapered" snap ring from the case that retains the low/reverse clutch housing in transmission case (See Figure 45).

50. Remove low/reverse clutch housing assembly from the transmission case by lifting straight up, as shown in Figure 45, and set aside for component disassembly.

1

51. Remove the park rod retaining "E" clip from the manual lever as shown in Figures 46 & 47.

52. Remove the park rod from the transmission as shown in Figures 46 and 47.

53. Remove the manual shaft and lever assembly retaining pin bolt using a 30 Torx bit as shown in Figures 46 and 47.

54. Remove the manual shaft and lever assembly through the inside of the case. Refer to Figures 46 and 47.

55. Remove and discard the manual shaft seal as shown in Figure 47.

1

2

1. INPUT INTERNAL RING GEAR ASSEMBLY.

2. NUMBER 12 THRUST BEARING.

Figure 44 Figure 45

40

1. LOW/REVERSE CLUTCH HOUSING "TAPERED" SNAP RING.

2. LOW/REVERSE CLUTCH HOUSING ASSEMBLY.

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

56. Remove the park rod guide retaining snap ring from the case as shown in Figure 47.

57. Remove the park rod guide from the case, as shown in Figure 47.

3

1

4

1. PARK ROD RETAINING "E" CLIP.

2. MANUAL SHAFT RETAINING PIN BOLT (30 TORX).

3. MANUAL SHAFT AND LEVER ASSEMBLY.

2

Figure 46

2

1 3

4

5

6

1. PARK ROD RETAINING "E" CLIP.

2. MANUAL SHAFT RETAINING PIN BOLT (30 TORX).

3. MANUAL SHAFT AND LEVER ASSEMBLY.

4. PARK ROD ASSEMBLY.

5. PARK PAWL ROD GUIDE.

6. PARK PAWL ROD GUIDE RETAINING SNAP RING.

7. MANUAL SHAFT SEAL.

7

Figure 47

AUTOMATIC TRANSMISSION SERVICE GROUP

41

Technical Service Information

3

1

4

1. PARK ROD RETAINING "E" CLIP.

2. MANUAL SHAFT RETAINING PIN BOLT (30 TORX).

3. MANUAL SHAFT AND LEVER ASSEMBLY.

2

Figure 48 Figure 49

COMPONENT REBUILD

TRANSMISSION CASE ASSEMBLY

1. Clean and inspect all components. Replace any parts which show evidence of damage or wear.

2. Install the park rod guide into the transmission case, as shown in Figure 47.

3. Install the park rod guide retaining snap ring into the case using a pair of pliers and insure that it is seated in the groove (See Figure 49).

4. Install a new manual shaft seal into the case using the proper size seal driver and insure that it is fully seated in bore (See Figure 47).

5. Lubricate the manual shaft lever seal with a small amount of TransJel®.

6. Install the manual shaft and lever assembly through the inside of case and into the manual shaft case bore as shown in Figure 47.

7. Install the manual shaft and lever assembly retaining pin bolt, using a 30 Torx bit, torque to 28.2 Nm (250 in lbs). (See Figure 48)

8. Install park rod through park rod guide and the parking pawl, and onto the pin on manual lever. Refer to Figures 48 and 49.

9. Install the retaining "E" clip and insure that it is fully seated as shown in Figure 48.

10. Ensure that the parking linkage works freely and set case aside for final assembly.

LOW/REVERSE CLUTCH HOUSING ASSEMBLY

1. Remove the inner overrunning clutch snap ring from the low/reverse clutch housing. This snap ring is item 16 in Figure 50.

2. Remove the outer low/reverse backing plate snap ring from the low/reverse clutch housing. This snap ring is item 11 in Figure 50.

3. Remove the low/reverse clutch pack and the low overrun clutch assembly together as an assembly (See Figure 50).

4. Seperate the low/reverse clutch pack from the low overrun clutch assembly.

5. Remove the overrun clutch snap ring from the inner race. This snap ring is item 15 in Figure

50.

6. Remove the spacer washer from the overrun clutch assembly, item 16 in Figure 50.

7. Seperate the inner and outer races of overrun clutch assembly.

8. Remove the lower overrun clutch snap ring from the low/reverse clutch housing, item 7 in Figure 50.

9. Using a sutiable shop press, compress the low reverse bellville plate and remove the "split" retaining ring, remove the bellville plate and the piston from housing (See Figure 50).

10. Remove and discard both piston seals.

42

Continued on Page 44.

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

LOW/REVERSE CLUTCH HOUSING EXPLODED VIEW

11

2345

1

67810

1. LOW/REVERSE CLUTCH HOUSING

2. LOW/REVERSE CLUTCH PISTON OUTER "D" RING

3. LOW/REVERSE CLUTCH PISTON

4. LOW/REVERSE CLUTCH PISTON INNER "D" RING

5. LOW/REVERSE CLUTCH BELLVILLE PLATE

6. LOW/REVERSE BELLVILLE PLATE "SPLIT" RETAINING RING

7. LOW ROLLER CLUTCH LOWER SNAP RING

8. LOW/REVERSE CLUTCH STEEL PLATES (6 REQUIRED)

9

1213141516

9. LOW/REVERSE CLUTCH FRICTION PLATES (6 REQUIRED)

10. LOW/REVERSE CLUTCH BACKING PLATE

11. LOW/REVERSE CLUTCH BACKING PLATE SNAP RING

12. LOW ROLLER CLUTCH AND INNER RACE ASSEMBLY

13. LOW ROLLER CLUTCH OUTER RACE

14. SPACER WASHER

15. LOW ROLLER INNER RACE RETAINING SNAP RING

16. LOW ROLLER CLUTCH UPPER SNAP RING

Figure 50

AUTOMATIC TRANSMISSION SERVICE GROUP

43

Technical Service Information

ROLLER CLUTCH

"LOWER" SNAP RING

LOW/REVERSE

"SPLIT" RING

LOW/REVERSE

BELLVILLE PLATE

LOW/REVERSE

INNER SEAL

LOW/REVERSE

PISTON

LOW/REVERSE

OUTER SEAL

LOW/REVERSE CLUTCH HOUSING ASSEMBLY (Cont'd)

1. Clean and inspect all low/reverse clutch parts. Replace any components that show evidence of wear or damage.

2. Check the bleed orifice in the bottom of the low/reverse clutch housing to ensure that it is not plugged or restricted (See Figure 52).

3. Install new inner and outer seals onto the low reverse piston and lubricate with small amount of TransJel® (See Figure 51).

4. Install the low/reverse piston assembly into the low/reverse clutch housing (See Figure 51).

5. Install the bellville plate on top of the piston as shown in Figure 51.

6. Compress the low/reverse piston bellville plate and install the split retaining ring to hold the bellville spring in the clutch housing. Refer to Figures 51 and 53.

7. Install the "lower" overrunning clutch snap ring into the groove directly above the split ring in the low/reverse clutch housing.

8. Install the inner race into the outer race. While holding the inner race, rotate the outer race in a clockwise direction to install (See Figure 55).

9. Install the spacer washer on top of the outer race as shown in Figure 55.

10. Install the low roller clutch inner race retaining snap ring into the groove above the spacer as shown in Figure 54 and 55.

LOW/REVERSE

44

HOUSING

BLEED ORIFICE

Figure 51 Figure 52

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

11. Check for proper low roller clutch operation, and set aside for installation after clutch plates are installed.

NOTE: When the low roller clutch is properly assembled the outer race should freewheel in a clockwise direction while holding the inner race.

We have provided you with a snap ring chart with dimensions to identify all snap rings in the Low/ Reverse clutch housing in Figure 58.

Continued on Page 46.

"SPLIT" RING

INSTALLED

10 1

8

V1C

A

9 67 399

4

1 5

LOW ROLLER CLUTCH ASSEMBLY

4

3

2

Figure 53

WHEN ASSEMBLED CORRECTLY OUTER RACE

WILL FREEWHEEL CLOCKWISE

FREEWHEELHOLD

AUTOMATIC TRANSMISSION SERVICE GROUP

1

1. LOW ROLLER CLUTCH AND INNER RACE ASSEMBLY.

2. LOW ROLLER CLUTCH OUTER RACE.

3. SPACER WASHER.

Figure 55Figure 54

45

Technical Service Information

5

LOW/REVERSE CLUTCH HOUSING ASSEMBLY (Cont'd)

12. Install the low/reverse clutch pack beginning with a steel plate and alternating with a friction plate, until you have installed six of each, as shown in Figure 56.

13. Install the low/reverse backing plate with the

4

inside bevel facing up as shown in Figure 56.

14. Install the low/reverse backing plate snap ring as shown in Figure 56. This is a selective snap ring to adjust clutch clearance.

15. Low/reverse clutch clearance should measure

1.00-7.74 mm (.039"-.069").

LOW ROLLER CLUTCH

"UPPER" SNAP RING

LOW ROLLER

3

CLUTCH ASSEMBLY

2

ONE WIDE

1

SPLINE

1. LOW/REVERSE CLUTCH HOUSING.

2. LOW/REVERSE STEEL PLATES (6 REQUIRED).

3. LOW/REVERSE FRICTION PLATES (6 REQUIRED).

4. LOW/REVERSE BACKING PLATE.

Figure 56 Figure 57

46

AUTOMATIC TRANSMISSION SERVICE GROUP

Snap Ring No. 1 Snap Ring No. 2 Snap Ring No. 3 Snap Ring No. 4 Snap Ring No. 5 Snap Ring No. 6

Technical Service Information

LOW/REVERSE CLUTCH HOUSING SNAP RING IDENTIFICATION

Thickness

"Split" Ring

Flat .061" Flat .061" Flat .038" Flat .080"

Tapered .080"

I.D. to O.D. Notes:

.154" .154" .187" .186" .188"

Same as Ring No. 2.

Retains the housing in case.

Snap Ring No. 6

Snap Ring No. 5 Snap Ring No. 4

Snap Ring No. 3

Case

16. Install the low roller clutch assembly into the low/reverse clutch housing by rotating outer race clockwise to engage each of the friction plates until it is fully seated.

17. The low/reverse clutch housing has one wider spline on the inner hub where the inner race splines to it, and the inner race must be turned to engage the splines (See Figure 57). This is done to ensure alignment of the lube holes.

18. After the low roller clutch assembly is fully seated, install the "upper" overrun clutch snap ring into the groove (See Figure 57).

19. Set the completed low/reverse clutch housing aside for final assembly (See Figure 59).

Snap Ring No. 2

Snap Ring No. 1

(Split Ring)

Low/Reverse

Clutch Housing

Figure 58

COMPLETED LOW/REVERSE CLUTCH HOUSING

Figure 59

AUTOMATIC TRANSMISSION SERVICE GROUP

47

Technical Service Information

2-4 CLUTCH RETAINER EXPLODED VIEW

4

3

2

7891011

1

56

48

121415

13

Figure 60

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

2-4 CLUTCH RETAINER EXPLODED VIEW

21

17

20

COMPLETED 2-4

RETAINER ASSEMBLY

18

16

1. 2-4 CLUTCH RETAINER ASSEMBLY.

2. 2ND CLUTCH PISTON OUTER "D" RING SEAL.

3. 2ND CLUTCH PISTON INNER "D" RING SEAL.

4. 2ND CLUTCH PISTON.

5. 2ND CLUTCH BELLVILLE PLATE.

6. 2ND CLUTCH BELLVILLE PLATE RETAINING SNAP RING.

7. 4TH CLUTCH PISTON OUTER "D" RING SEAL (GOES IN SUPPORT).

8. 4TH CLUTCH PISTON INNER "D" RING SEAL.

9. 4TH CLUTCH PISTON.

10. 4TH CLUTCH PISTON RETURN SPRING ASSEMBLY.

11. 4TH CLUTCH PISTON RETURN SPRING RETAINING SNAP RING.

AUTOMATIC TRANSMISSION SERVICE GROUP

19

12. 4TH CLUTCH STEEL PLATES .098" THICK (3 REQUIRED).

13. 4TH CLUTCH FRICTION PLATES .090" THICK (3 REQUIRED).

14. 4TH CLUTCH PRESSURE PLATE .196" THICK.

15. 4TH CLUTCH PRESSURE PLATE "FLAT" SNAP RING (SELECTIVE).

16. 2-4 SUPPORT ASSEMBLY "TAPERED" SNAP RING (GOES IN CASE).

17. NUMBER 6 THRUST BEARING.

18. 2ND CLUTCH STEEL PLATES .127" THICK (2 REQUIRED).

19. 2ND CLUTCH FRICTION PLATES .092" THICK (2 REQUIRED).

20. 2ND CLUTCH PRESSURE PLATE (SELECTIVE)

21. 2-4 SUPPORT ASSEMBLY "FLAT" SNAP RING (GOES IN CASE).

Figure 61

49

Technical Service Information

2-4 CLUTCH RETAINER ASSEMBLY

6

5

4

2

3

1. Disassemble the 2-4 clutch retainer using the illustrations in Figures 60 and 61.

2. Clean and inspect all components and replace those components that show wear or damage.

3. Install new inner and outer seals on 2nd clutch piston, as shown in Figure 62, and lubricate with small amount of TransJel®.

4. Install the 2nd clutch piston in the 2-4 retainer as shown in Figure 62.

5. Install the 2nd clutch piston bellville plate on top of the 2nd clutch piston in retainer.

6. Position the 2nd clutch bellville plate snap ring on top of the bellville plate (See Figure 63).

7. Using a suitable shop press, compress bellville spring until the snap ring is engaged into the snap ring groove in the 2-4 retainer, and ensure that it is fully seated as shown in Figure 63.

8. Install new inner and outer seals on 4th clutch piston, as shown in Figure 65, and lubricate with small amount of TransJel®.

9. Install the 4th clutch piston in the 2-4 retainer as shown in Figure 65.

10. Install the 4th clutch piston return spring on top of the piston as shown in Figure 65.

11. Position the return spring retaining snap ring on top of the return spring (See Figure 65).

1

1. 2-4 CLUTCH RETAINER ASSEMBLY.

2. 2ND CLUTCH PISTON OUTER SEAL.

3. 2ND CLUTCH PISTON INNER SEAL

4. 2ND CLUTCH PISTON.

5. 2ND CLUTCH PISTON BELLVILLE PLATE.

6. 2ND CLUTCH PISTON BELLVILLE PLATE SNAP RING.

50

AUTOMATIC TRANSMISSION SERVICE GROUP

BELLVILLE

PLATE

BELLVILLE PLATE

SNAP RING

Figure 63Figure 62

Technical Service Information

12. Using a suitable shop press, compress the 4th clutch return spring, and install the snap ring into the groove in the 2-4 retainer.

13. Ensure that the snap ring is fully seated, as shown in Figure 64.

Continued on Page 52.

6

5

4

2

4TH CLUTCH

RETURN SPRING

3

1

RETURN SPRING

SNAP RING

1. 2ND AND 4TH CLUTCH RETAINER ASSEMBLY.

2. 4TH CLUTCH PISTON OUTER SEAL.

3. 4TH CLUTCH PISTON INNER SEAL.

4. 4TH CLUTCH PISTON.

5. 4TH CLUTCH PISTON RETURN SPRING ASSEMBLY.

6. 4TH CLUTCH PISTON RETURN SPRING RETAINING SNAP RING.

Figure 64 Figure 65

AUTOMATIC TRANSMISSION SERVICE GROUP

51

Technical Service Information

2-4 CLUTCH RETAINER ASSEMBLY (Cont'd)

5

4

14. Install the 4th clutch pack beginning with a steel plate and alternating with friction plate until you have installed three of each plate, as shown in Figure 66.

15. Install the 4th clutch backing plate, as shown in Figure 66. This plate is non-directional and will go in either way.

16. Install the 4th clutch backing plate selective snap ring as shown in Figure 66, and ensure that it is fully seated.

17. Measure the 4th clutch clearance. The correct clutch clearance is 0.770-1.390 (.030"-.055").

18. Change the snap ring as necessary and verify clutch clearance by re-measuring.

19. Set the completed 2-4 retainer assembly aside for final assembly (See Figure 67.

3

2

1

COMPLETED 2-4 CLUTCH RETAINER ASSEMBLY

1. 2-4 CLUTCH RETAINER ASSEMBLY.

2. 4TH CLUTCH STEEL PLATES .098" THICK (3 REQUIRED).

3. 4TH CLUTCH FRICTION PLATES .090" THICK (3 REQUIRED).

4. 4TH CLUTCH BACKING PLATE .196" THICK.

52

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 67Figure 66

Technical Service Information

GEAR TRAIN COMPONENTS

1. Clean and inspect all geartrain components as shown in Figure 68. Replace any components that show evidence of wear or damage.

GEAR TRAIN COMPONENTS EXPLODED VIEW

16

2. Set all inspected geartrain parts aside for the final assembly process.

12

1314151718

11

910

8

4

3

67

2

1

5

1. PARK GEAR RETAINING SNAP RING.

2. PARK GEAR ASSEMBLY.

3. NUMBER 12 THRUST BEARING.

4. INPUT INTERNAL RING GEAR.

5. INPUT PLANETARY CARRIER/REVERSE INTERNAL RING GEAR.

6. NUMBER 11 THRUST BEARING.

7. INPUT SUN GEAR.

8. NUMBER 10 THRUST BEARING.

9. REVERSE PLANETARY CARRIER ASSEMBLY.

AUTOMATIC TRANSMISSION SERVICE GROUP

10. REVERSE CARRIER/INPUT RING GEAR "FLAT" SNAP RING.

11. NUMBER 9 THRUST BEARING.

12. REACTION CARRIER/REVERSE SUN GEAR ASSEMBLY.

13. NUMBER 8 THRUST BEARING.

14. REACTION SUN GEAR.

15. NUMBER 7 THRUST BEARING.

16. REACTION INTERNAL RING GEAR ASSEMBLY.

17. SELECTIVE THRUST WASHER PLATE.

18. NUMBER 6 THRUST BEARING.

Figure 68

53

Technical Service Information

INPUT CLUTCH HOUSING COMPONENTS EXPLODED VIEW

9

2

1

3

6

4

5

4799090

87

18

34

19

35

37 38

20

21

22

23

24

54

36

Figure 69

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

INPUT CLUTCH HOUSING COMPONENTS EXPLODED VIEW

10

25

11

4799090

26

12

27

13

14

29 30 31

15

16

17

33

32

1. NUMBER 1 THRUST BEARING.

2. INPUT CLUTCH HUB.

3. GREEN COLORED "O" RING.

4. RED COLORED "O" RING.

5. INPUT SHAFT RETAINING CIR-CLIP.

6. REVERSE OUTER LIP SEAL (INSIDE LIP).

7. OVERDRIVE/REVERSE PISTON BELLVILLE SNAP RING.

8. OVERDRIVE/REVERSE PISTON BELLVILLE PLATE.

9. OVERDRIVE/REVERSE PISTON ASSEMBLY.

10. OVERDRIVE OUTER LIP SEAL (INSIDE LIP).

11. OVERDRIVE/REVERSE INNER "O" RING.

12. INPUT CLUTCH RETAINER.

13. "BEVELED" SNAP RING (INSIDE BEVEL).

14. UNDERDRIVE CLUTCH PISTON ASSEMBLY.

15. UNDERDRIVE CLUTCH RETURN SPRING ASSEMBLY.

16. SPRING RETAINER AND BALANCE PISTON ASSEMBLY.

17. "FLAT" SNAP RING.

18. NUMBER 2 THRUST BEARING.

28

20. UNDERDRIVE CLUTCH STEEL PLATES .067" THICK (4 REQUIRED).

21. UNDERDRIVE CLUTCH LINED PLATES .078" THICK (4 REQUIRED).

22. UNDERDRIVE/OVERDRIVE REACTION PLATE "FLAT" SNAP RING.

23. UNDERDRIVE/OVERDRIVE REACTION PLATE.

24. UNDERDRIVE/OD REACTION PLATE "TAPERED" SNAP RING.

25. NUMBER 3 THRUST BEARING.

26. OVERDRIVE CLUTCH HUB AND SHAFT ASSEMBLY.

27. OVERDRIVE CLUTCH STEEL PLATES .086" THICK (3 REQUIRED).

28. OVERDRIVE CLUTCH LINED PLATES .090" THICK (4 REQUIRED).

29. OVERDRIVE/REVERSE REACTION PLATE "WAVE" SNAP RING.

30. OVERDRIVE/REVERSE REACTION PLATE.

31. OVERDRIVE/REVERSE REACTION PLATE "FLAT" SNAP RING.

32. NUMBER 4 THRUST BEARING.

33. REVERSE CLUTCH HUB ASSEMBLY.

34. NUMBER 5 "SELECTIVE" THRUST BEARING ASSEMBLY .

35. REVERSE CLUTCH STEEL PLATE .067" THICK (1 REQUIRED).

36. REVERSE CLUTCH LINED PLATES .080" THICK (2 REQUIRED).

37. REVERSE CLUTCH BACKIG PLATE.

38. REVERSE CLUTCH BACKING PLATE "FLAT" SNAP RING.

Figure 70

AUTOMATIC TRANSMISSION SERVICE GROUP

55

Technical Service Information

INPUT CLUTCH HOUSING

SNAP RING IDENTIFICATION CHART

Snap Ring No. 1 Snap Ring No. 2 Snap Ring No. 3 Snap Ring No. 4 Snap Ring No. 5 Snap Ring No. 6 Snap Ring No. 7 Snap Ring No. 8

Thickness Flat .060"

Tapered .091"

Flat .078" Flat .060"

Tapered .095"

Waved .060"

Flat .060" Flat .072"

I.D. to O.D.

.187" Varies Varies

.189"

.139"

.155"

.186"

.187"

Snap Ring No. 8

Snap Ring No. 7

Snap Ring No. 6

Snap Ring No. 5

Snap Ring No. 4

Snap Ring No. 3

Snap Ring No. 2

Snap Ring No. 1

56

Figure 71

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

5

4799090

INPUT CLUTCH HOUSING ASSEMBLY

1. Disassemble the input clutch housing using the illustrations in Figures 69 and 70 as a guide.

2. Clean and inspect all components. Replace any parts that show evidence of wear or damage.

3. Remove the small "eyelet" snap ring from the input shaft as shown in Figure 72.

4. Remove the drain back ball capsule assembly from the input shaft using a pick tool. Remove and discard the "O" ring (See Figure 72).

5. Install a new "O" ring on the ball capsule and lubricate with small amount of TransJel®.

4

6. Install the drain back ball capsule back into the input shaft in the direction shown in Figure 72.

7. Install the "eyelet" snap ring and ensure that it

3

is fully seated (See Figure 72).

8. Install new lip seal into the groove in the input

2

clutch hub with the lip facing down as shown in Figure 72 and lubricate with a small amount of TransJel®.

9. The "O" rings on the input clutch hub are color coded. Install Green and Red colored "O" rings

1

in the positions shown in Figure 73, and lube with a small amount of TransJel®.

1. INPUT CLUTCH HUB/ INPUT SHAFT ASSEMBLY.

2. DRAIN BACK BALL CAPSULE, WITH "O" RING ASSEMBLY.

3. BALL CAPSULE ASSEMBLY RETAINING SNAP RING.

4. CIR-CLIP TO RETAIN INPUT SHAFT.

5. REVERSE OUTER LIP SEAL (INSIDE LIP).

RED COLORED

"O" RING

Continued on Page 58.

GREEN COLORED

"O" RING

Figure 72 Figure 73

AUTOMATIC TRANSMISSION SERVICE GROUP

57

Technical Service Information

INPUT CLUTCH HOUSING ASSEMBLY (Cont'd)

10. Install the overdrive/reverse bellville plate and

4

5

3

4799090

the retaining snap ring as shown in Figure 74, if they were removed.

11. Install the overdrive outer lip seal into groove inside the overdrive/reverse piston, with the lip facing down, as shown in Figure 74.

12. Install the overdrive/reverse inner "O" ring seal into the groove in the overdrive/reverse piston as shown in Figure 74.

13. Lubricate both seals with small amount of TransJel®.

14. Install the input clutch retainer into overdrive/ reverse piston by rotating into position, as shown in Figure 75.

15. Install input clutch retainer and OD/Reverse piston assembly onto the input clutch hub, as shown in Figure 76.

16. Install the input clutch retainer tapered snap ring, with the tapered side facing up, into the groove in the input clutch hub as shown in Figure 76.

Special Note: We have provided you with a snap ring identification chart to identify the snap rings, and identify their locations, in Figure 71 on Page 56. This chart will identify

all snap rings in the input housing.

2

1

INPUT CLUTCH

RETAINER

1. OVERDRIVE/REVERSE PISTON BELLVILLE PLATE SNAP RING.

2. OVERDRIVE/REVERSE PISTON BELLVILLE PLATE.

3. OVERDRIVE/REVERSE PISTON ASSEMBLY.

4. OVERDRIVE OUTER LIP SEAL (INSIDE LIP).

5. OVERDRIVE/REVERSE INNER "O" RING SEAL.

Figure 74 Figure 75

58

AUTOMATIC TRANSMISSION SERVICE GROUP

OVERDRIVE/REVERSE

PISTON ASSEMBLY

Technical Service Information

17. Install the input clutch molded rubber piston in input clutch retainer as shown in Figure 77.

18. Install the input clutch piston return spring on top of the input clutch piston (See Figure 77).

19. Install the spring retainer/balance piston, as shown in Figure 77. The balance piston also has a molded seal.

20. Using a suitable shop press, compress return spring assembly and install the flat snap ring into the groove. Refer to Figure 77 and snap ring chart in Figure 71.

Continued on Page 60.

TAPERED EYELET

SNAP RING

INPUT CLUTCH RETAINER

AND OD/REVERSE PISTON

4

3

2

1

INPUT CLUTCH HUB

1. INPUT CLUTCH STAMPED STEEL MOLDED RUBBER PISTON.

2. INPUT CLUTCH PISTON RETURN SPRING ASSEMBLY.

3. RETURN SPRING RETAINER AND BALANCE PISTON ASSEMBLY.

4. BALANCE PISTON RETAINING SNAP RING.

Figure 76 Figure 77

AUTOMATIC TRANSMISSION SERVICE GROUP

59

Technical Service Information

5

INPUT CLUTCH HOUSING ASSEMBLY (Cont'd)

21. Install the underdrive clutch pack starting with a steel plate and alternating with a lined plate until you have installed four of each, as shown in Figure 78. Note that the underdrive steel

4

plates have a half-moon cut in each of the tabs.

22. Install the underdrive/overdrive reaction plate lower flat snap ring into the housing in the lower groove (See Figure 78).

3

Special Note: We have provided you with a snap ring identification chart to identify the snap rings, and identify their locations, in Figure 71 on Page 56. This chart will identify all snap rings in the input housing.

23. Install the underdrive/overdrive reaction plate into the input clutch retainer, with the big step facing down as shown in Figure 78. This plate

2

1

is also selective to achieve proper underdrive clutch clearance.

24. Install the underdrive/overdrive reaction plate upper tapered snap ring into the housing with the tapered side facing up (See Figure 78).

Special Note: We have provided you with a snap ring identification chart to identify the snap rings, and identify their locations, in Figure 71 on Page 56. This chart will identify

all snap rings in the input housing.

25. Mount a dial indicator to the assembly and zero the the indicator against the tooth of the clutch friction disc. Apply 20 psi of air pressure to the underdrive clutch and record the dial reading.

26. The correct underdrive clutch clearance should be 0.84-1.54 mm (.033"-.061").

27. Adjust as necessary by changing the reaction plate and re-measure to verify proper clearance. NOTE: The Underdrive - Overdrive friction

and steel plates are not the same do not mis- stack or binding and or neutraling shifts may occur.

1. UNDERDRIVE CLUTCH STEEL PLATES, .067" THICK (4 REQUIRED).

2. UNDERDRIVE CLUTCH LINED PLATES, .078" THICK (4 REQUIRED).

3. UNDERDRIVE/OVERDRIVE REACTION PLATE "FLAT" SNAP RING.

4. UNDERDRIVE/OVERDRIVE REACTION PLATE (SELECTIVE)

Figure 78

60

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

28. Install the overdrive clutch pack starting with a lined plate and alternating with steel plates until you have installed 4 lined and 3 steel plates, as shown in Figure 79. Note that the overdrive plates do not have the half-moon cut on tabs.

29. Install the overdrive/reverse reaction plate wave snap ring into the wide groove in the overdrive/reverse piston and push the snap ring to the bottom of the groove (See Figure 79).

5

4

Special Note: We have provided you with a snap ring identification chart to identify the snap rings, and identify their locations, in Figure 71 on Page 56. This chart will identify all snap rings in the input housing.

30. Install the overdrive/reverse reaction plate into the retainer as shown in Figure 79. The reaction plate is non-directional and can be installed in either direction.

31. Install the overdrive/reverse reaction plate flat snap ring on top of the reaction plate and into wide groove in overdrive/reverse piston, by pushing down on the reaction plate to pre-load the wave snap ring.

Special Note: We have provided you with a snap ring identification chart to identify the snap rings, and identify their locations, in Figure 71 on Page 56. This chart will identify all snap rings in the input housing.

32. Mount a dial indicator to the assembly and zero the indicator against the OD/reverse reaction plate. Apply 20 psi of air pressure to the over drive clutch and record the indicator reading.

33. The correct overdrive clutch clearance should be 1.103-1.856 mm (.043"-.073").

34. There are no selectives for the overdrive clutch pack. If the overdrive clutch clearance is not correct, you have something mis-assembled. NOTE: The Underdrive - Overdrive friction

and steel plates are not the same do not mis- stack or binding and or neutraling shifts may occur.

3

1

2

Continued on Page 62.

AUTOMATIC TRANSMISSION SERVICE GROUP

1. OVERDRIVE CLUTCH STEEL PLATES .086" THICK (3 REQUIRED).

2. OVERDRIVE CLUTCH LINED PLATES .090" THICK (4 REQUIRED).

3. OVERDRIVE/REVERSE REACTION PLATE "WAVE" SNAP RING.

4. OVERDRIVE/REVERSE REACTION PLATE.

5. OVERDRIVE/REVERSE REACTION PLATE "FLAT" SNAP RING.

Figure 79

61

Technical Service Information

INPUT CLUTCH HOUSING ASSEMBLY (Cont'd)

4

3

1

2

35. Install the reverse clutch pack beginning with a lined plate and alternating with steel plate until you have installed two lined plates and 1 steel plate, as shown in Figure 80.

36. Install the reverse clutch backing plate with the flat side down, as shown in Figure 80.

37. Install reverse clutch backing plate selective snap ring as shown in Figure 80.

Special Note: We have provided you with a snap ring identification chart to identify the snap rings, and identify their locations, in Figure 71 on Page 56. This chart will identify all snap rings in the input housing.

38. Mount a dial indicator to the assembly and zero the the indicator against the tooth of the clutch friction disc. Apply 20 psi of air pressure to the reverse clutch and record the dial reading.

39. The correct reverse clutch clearance should be

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

40. Adjust as necessary by changing backing plate selective snap ring and re-measure to verify the proper reverse clutch clearance.

41. Remove the reverse clutch pack from the input housing assembly to install the 3 clutch hubs and shafts.

42. Install the number 2 thrust bearing into the underdrive clutch hub and shaft, in direction shown in Figure 81, and retain with TransJel®.

43. Install the underdrive clutch hub and shaft into input housing, by turning until all underdrive clutches are engaged and it is fully seated.

44. Install the number 3 thrust bearing into the overdrive clutch hub and shaft, in the direction shown in Figure 82, and retain with TransJel®.

45. Install the overdrive clutch hub and shaft into input housing, by turning until all overdrive clutches are engaged and it is fully seated.

1. REVERSE CLUTCH STEEL PLATE .067" THICK (1 REQUIRED).

2. REVERSE CLUTCH LINED PLATES .080" THICK (2 REQUIRED).

3. REVRESE CLUTCH BACKING PLATE.

Figure 80

62

AUTOMATIC TRANSMISSION SERVICE GROUP

Continued on page 64.

Technical Service Information

2

1

1. NUMBER 2 THRUST BEARING ASSEMBLY.

2. UNDERDRIVE CLUTCH HUB AND SHAFT ASSEMBLY.

Figure 81 Figure 82

AUTOMATIC TRANSMISSION SERVICE GROUP

1. NUMBER 3 THRUST BEARING ASSEMBLY.

2. OVERDRIVE CLUTCH HUB AND SHAFT ASSEMBLY.

63

Technical Service Information

INPUT CLUTCH HOUSING ASSEMBLY (Cont'd)

46. Install the number 4 thrust bearing into reverse clutch hub, in the direction shown in Figure 83,

2

1

and retain with small amount of TransJel®.

47. Install the reverse clutch hub assembly into the input housing over both shafts, as shown in Figure 83.

48. Re-install the reverse clutch pack completely as shown in Figure 80.

49. Install the number 5 selective thrust bearing on the back side of reverse clutch hub as shown in Figure 84 and retain with TransJel®.

50. Set the completed input housing assembly aside for the final assembly process.

SELECTIVE THRUST BEARING

FOR FRONT END CLEARANCE

1. NUMBER 4 THRUST BEARING ASSEMBLY.

2. REVERSE CLUTCH HUB ASSEMBLY.

Figure 83 Figure 84

64

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

OIL PUMP ASSEMBLY EXPLODED VIEW

2

3

4

5

1

021

3

8

3

2

5

C

9

1

R

9

-

7

1

2

A

6

4

6

2

4

7

8

10

9

1. FRONT OIL PUMP CONVERTER SEAL.

2. PUMP BODY TO PUMP COVER RETAINING BOLTS (24 REQUIRED).

3. OIL PUMP BODY ASSEMBLY.

4. PUMP BODY TO PUMP COVER "HOLLOW" DOWELS (2 REQUIRED).

5. OIL PUMP DRIVE GEAR.

6. OIL PUMP DRIVEN GEARS.

7. OIL PUMP SHUTTLE VALVE.

8. OIL PUMP SPACER PLATE.

9. OIL PUMP SPACER PLATE RETAINING BOLTS (2 REQUIRED).

10. OIL PUMP COVER ASSEMBLY.

11. PUMP STATOR ASSEMBLY.

12. PUMP STATOR SEALING RINGS (5 REQUIRED). NOTE: Early pump shown

Figure 85

AUTOMATIC TRANSMISSION SERVICE GROUP

11

12

13

65

Technical Service Information

FRONT PUMP

CONVERTER SEAL

16

4

6

1

7

9

1 9

2 3

3

8

5

C R

-

2

A

1 2

0

2

SHUTTLE

VALVE

Figure 86 Figure 87

PUMP COVER ASSEMBLY EXPLODED VIEW

PUMP COVER

3

16

1

32

FREE LENGTH = 1.177"

SPRING DIAMETER = .428"

WIRE DIAMETER = .040"

COLOR I.D. = WHITE

LEGEND FOR FIGURES 88 AND 89

1. TORQUE CONVERTER CLUTCH SWITCH VALVE.

2. TORQUE CONVERTER CLUTCH SWITCH VALVE SPRING.

3. SWITCH VALVE RETAINER, .588" WIDE, .062" THICK.

4. TORQUE CONVERTER CLUTCH CONTROL VALVE SPRING.

5. TORQUE CONVERTER CLUTCH CONTROL VALVE.

6. TORQUE CONVERTER CLUTCH CONTROL VALVE RETAINER.

7. TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE.

8. TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE SPRING.

9. TCC ACCUMULATOR VALVE RETAINER, .530" WIDE, .062" THICK.

10. TORQUE CONVERTER CLUTCH LIMIT VALVE.

11. TORQUE CONVERTER CLUTCH LIMIT VALVE SPRING.

12. LIMIT VALVE RETAINER, .588" WIDE, .062" THICK.

13. MAIN PRESSURE REGULATOR VALVE.

14. MAIN PRESSURE REGULATOR VALVE SPRING.

15. REGULATOR VALVE RETAINER, .666" WIDE, .062" THICK.

16. PUMP BODY TO PUMP COVER "HOLLOW" DOWELS (2 REQUIRED).

66

Figure 88

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

OIL PUMP AND COVER ASSEMBLY

1. Disassemble the complete oil pump assembly using Figure 85 as a guide. Note: Early pump

illustrated.

2. Remove all valves and springs from the pump cover using Figures 88 and 89 as a guide.

3. Clean and inspect all components. Replace any parts that show wear or damage.

4. Notice that there is not a pump body bushing, but there are bushings in the stator to inspect.

5. Install a new converter seal into the pump body using the proper driver as shown in Figure 86.

6. Dip all 3 of the oil pump gears into Mopar® ATF+3+4, type 7176 transmission fluid and install into their original locations (See Figure 87).

7. Install the oil pump shuttle valve into the pump cavity shown in Figures 87 and 88.

8. Lubricate all valves that go into the pump cover with Mopar® ATF+3+4, type 7176 transmission fluid, as well as the pump cover valve bores.

9. Install all springs, valves and retainers exactly as shown in Figures 88 and 89. Notice that the valve line-up retainers are different sizes for different locations, shown in Figure 88 legend.

10. Refer to Figure 90 for the exact cavity location in the pump cover for the various retainers.

Continued on Page 68.

PUMP COVER

PUMP COVER ASSEMBLY EXPLODED VIEW

FREE LENGTH = .860"

SPRING DIAMETER = .297"

WIRE DIAMETER = .031"

COLOR I.D. = NONE

FREE LENGTH = 1.100"

SPRING DIAMETER = .415"

WIRE DIAMETER = .057"

COLOR I.D. = NONE

Note: This spring is known

to break (Sonnax#44912-02)

FREE LENGTH = 1.279"

SPRING DIAMETER = .343"

WIRE DIAMETER = .043"

COLOR I.D. = NONE

Note: This spring is known

to break (Sonnax#44912-01)

10 11

94 5 6 7 8

12

13 14 15

Figure 89

AUTOMATIC TRANSMISSION SERVICE GROUP

FREE LENGTH = 2.265"

SPRING DIAMETER = .590"

WIRE DIAMETER = .058"

COLOR I.D. = NONE

67

TCC ACCUM VALVE RETAINER

.530" WIDE AND .62" THICK

Technical Service Information

PUMP COVER RETAINER LOCATIONS AND DEMENSIONS

LIMIT VALVE RETAINER

.588" WIDE AND .62" THICK

REGULATOR VALVE RETAINER

.666" WIDE AND .62" THICK

SWITCH VALVE RETAINER

.588" WIDE AND .62" THICK

SHUTTLE

VALVE

DOWEL DOWEL

2

3

Figure 91

Figure 90

OIL PUMP AND COVER ASSEMBLY (Cont'd)

11. Ensure that the shuttle valve is installed into the proper cavity in the oil pump body, and that the dowels are installed as shown in Figure 91.

12. Install the oil pump spacer plate onto the pump body over the dowels as shown in Figure 92.

13. Install the two screws to retain the spacer plate on the pump and torque to 4.5 Nm (40 in lbs). Refer to Figure 92. Note: Leaving these two

screws out will equal no engagement!

14. Install the pre-assembled oil pump cover onto the locating dowels as shown in Figure 93.

15. Seat the two oil pump halves together and very carefully turn the assembly over as shown in Figure 94. Start all 24 screws finger tight.

16. Torque all bolts slowly, starting in center and working out in a circle, to 4.5 Nm (40 in lbs). Refer to Figure 94.

Continued on Page 70.

68

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

SPACER PLATE

SCREWS

Do not leave

them out!

OIL PUMP

SPACER PLATE

OIL PUMP

COVER

2

3

2

3

Figure 92 Figure 93

TO PUMP COVER SCREWS

102

4

6

1

7

9

1 9

2 3 3

8

5

C R

-

2

A

OIL PUMP BODY

(24 REQUIRED)

Figure 94

AUTOMATIC TRANSMISSION SERVICE GROUP

69

Technical Service Information

OIL PUMP AND COVER ASSEMBLY (Cont'd)

18. Install the stator shaft support into the oil pump assembly as shown in Figure 95.

19. Install the 5 bolts that hold the stator support to the oil pump assembly as shown in Figure 95.

20. Torque the 5 stator shaft support bolts down to 12 Nm (105 in lbs).

21. Install five new sealing rings on stator support

2

1

in their respective grooves and ensure that they are properly hooked. Refer to Figure 96.

22. Set the completed oil pump assembly aside for the final assembly process (See Figure 97).

2

3

1. STATOR SHAFT ASSEMBLY.

2. STATOR SHAFT ASSEMBLY RETAINING BOLTS (5 REQUIRED).

Figure 95

70

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

2

3

STATOR SHAFT SEALING RINGS

(5 REQUIRED)

Figure 96

COMPLETED OIL PUMP ASSEMBLY

EARLY MODELS LATE MODELS

07 & UP

1 20

4

6

1 7

9

1

9

2 3 3

8 5

C

R

-

2

A

Figure 97

AUTOMATIC TRANSMISSION SERVICE GROUP

PUMP HAS NO HUB

TO RETAIN FRONT SEAL

102

71

Technical Service Information

VALVE BODY ASSEMBLY EXPLODED VIEW

2

3

1

4

05111

1

AK

4799655

98

5

6

9

7

1. VALVE BODY TRANSFER PLATE.

8

10

2. VALVE BODY ASSEMBLY SCREWS (50 REQUIRED).

3. 1/16" PIPE PLUGS (7 REQUIRED).

4. VALVE BODY SPACER PLATE.

5. 1/4" TORLON CHECK BALLS (7 REQUIRED).

6. VALVE BODY ASSEMBLY.

7. MANUAL VALVE DETENT SPRING.

8. MANUAL VALVE DETENT SPRING RETAINING BOLT.

9. TRANSMISSION RANGE SENSOR SELECTOR PLATE.

10. TRS SELECTOR PLATE "SHOULDERED" RETAINING BOLT.

72

Figure 98

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

VALVE BODY DISASSEMBLY

1. Remove the 15 screws that are shaded as shown in Figure 100. These screws must be removed first, so the TRS/Solenoid Body that contains most of the electrical components, will not be cleaned with any solvents.

2. Do Not remove the six screws from the top of the TRS/Solenoid Body (See Figure 99).

3. Once the TRS/Solenoid Body is separated from the valve body assembly, continue disassembly of the valve body using Figure 98 as a guide.

4. Notice in Figure 98 that the valve body contains seven checkballs. Care should be taken to keep the valve body in the position shown, when you are removing the transfer plate, so as not to lose any of the checkballs.

"DO NOT" REMOVE THESE SIX SCREWS

FROM TOP OF TRANSMISSION RANGE SENSOR

TRS/SOLENOID BODY

ASSEMBLY

3000 5%

"DO NOT" CLEAN WITH SOLVENT

Figure 99

3000 5%

COMPLETE VALVE BODY ASSEMBLY

05111

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98

REMOVE THE 15 SCREWS THAT

ARE SHADED TO REMOVE THE

TRANSMISSION RANGE SENSOR

Figure 100

AUTOMATIC TRANSMISSION SERVICE GROUP

73

Technical Service Information

MAIN VALVE BODY EXPLODED VIEW

1. MAIN VALVE BODY CASTING.

2. 1/4" TORLON CHECKBALLS (7 REQUIRED).

3. SOLENOID SWITCH VALVE LINE-UP.

4. SOLENOID SWITCH VALVE LINE-UP PLASTIC RETAINING CLIP.

5. MANUAL VALVE.

6. OVERDRIVE CLUTCH ACCUMULATOR PISTON AND SEALS.

7. OVERDRIVE CLUTCH ACCUMULATOR SPRING (SINGLE).

8. UNDERDRIVE CLUTCH ACCUMULATOR PISTON AND SEALS.

9. UNDERDRIVE CLUTCH ACCUMULATOR SPRINGS (DOUBLE).

10. 4TH CLUTCH ACCUMULATOR PISTON AND SEALS.

11. 4TH CLUTCH ACCUMULATOR SPRINGS (DOUBLE).

12. 2ND CLUTCH ACCUMULATOR PISTON AND SEALS.

13. 2ND CLUTCH ACCUMULATOR SPRINGS (DOUBLE.

14. LOW/REVERSE SWITCH VALVE.

15. LOW/REVERSE SWITCH VALVE BORE PLUG.

16. LOW/REVERSE ACCUMULATOR PISTON AND SEALS.

17. LOW/REVERSE ACCUMULATOR SPRINGS (DOUBLE).

18. ACCUMULATOR COVER PLATE.

2

4

5

3

1

6

7

8

10

12

14

15

9

16

11

13

17

74

Note: This plate is known

to distort/break and is available

from many aftermarket sources

18

19

Figure 98

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

VALVE BODY ASSEMBLY

1. Clean and inspect all components. Replace any parts that show evidence of wear or damage.

2. Lubricate the valves, springs and bore plugs with clean transmission fluid.

3. Install the solenoid switch valve and plugs into the valve body, exactly as shown in Figure 98, and then install the retainer.

4. Install the low/reverse switch valve into valve body as shown in Figure 98, followed by the bore plug. Some manuals illustrate a bore plug wire retainer for this location. Our unit did not have one, nor is it needed as the accumulator cover retains this valve train (See Figure 98).

5. Install the accumulator pistons and springs into the valve body in their proper locations, shown in Figure 98. Notice that all accumulators have two springs, except the overdrive, which has only one. Refer to Figure 98.

6. Install the accumulator cover onto valve body using the 7 retaining screws (See Figure 98).

7. Torque the screws to 4.5 Nm (40 in lbs).

8. Ensure that the solenoid switch valve and the low/reverse switch valve are free in their bores.

9. Lay the valve body down on a flat surface and install the 7 checkballs into the proper pockets as shown in Figure 99.

Continued on Page 77.

VALVE BODY CHECKBALL LOCATIONS

SWITCH VALVE

RETAINER

Figure 99

AUTOMATIC TRANSMISSION SERVICE GROUP

75

VALVE BODY

SPACER PLATE

Technical Service Information

TRANSFER

PLATE

Figure 100

05111

1

AK

4799655

98

76

Figure 101

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

VALVE BODY ASSEMBLY (Cont'd)

10. Install the valve body spacer plate over the locating dowels and onto the valve body as shown in Figure 100.

11. Install the transfer plate over locating dowels on the valve body as shown in Figure 101.

12. Install the 35 valve body to transfer plate bolts in the locations shown in Figure 102.

13. Torque the valve body to transfer plate bolts to

4.5 Nm (40 in lbs).

14. Turn the assembly over to continue assembly process.

Continued on Page 78.

TRANSFER PLATE TO VALVE BODY BOLT LOCATIONS

TRANSFER PLATE TO VALVE BODY

RETAINING SCREWS (35 REQUIRED)

05111

1

AK

4799655

98

Figure 102

AUTOMATIC TRANSMISSION SERVICE GROUP

77

Technical Service Information

VALVE BODY ASSEMBLY (Cont'd)

15. Install the manual valve into the manual valve bore in the valve body with the stem facing up and engaged in the groove (See Figure 103).

16. Install the transmission range sensor selector plate into the groove in the valve body and over the stem on the manual valve (See Figure 103).

17. Install the shouldered retaining bolt for the transmission range sensor selector plate and torque the bolt to 4.5 Nm (40 in lbs). Refer to Figure 103.

18. Install the manual valve detent spring and bolt and torque bolt to 4.5 Nm (40 in lbs). Refer to Figure 103.

19. Install the low/reverse seal into the valve body with the "house-top" facing up, as shown in Figure 104.

20. Install a new 2nd clutch seal and 4th clutch seal into the valve body with the "house-top facing up, as shown in Figure 104.

21. Install the TRS/Solenoid Pack onto the transfer plate using the remaining 15 valve body screws as shown in Figure 105.

22. Torque the TRS/Solenoid Pack screws down to

5.7 Nm (50 in lbs).

Important: Tighten the screws nearest the TRS selector plate first, and work toward the other end. Refer to Figure 105.

23. Testing procedures for the TRS/Solenoid Pack are found on Pages 18 and 19.

24. Set the completed valve body assembly aside for the final assembly process.

DETENT SPRING

SHOULDERED

BOLT

TRANSMISSION RANGE SENSOR

SELECTOR PLATE

MANUAL

VALVE

97

4799591

78

Figure 103

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

L/R Clutch

Seal

97

4799591

2nd Clutch

Seal

Figure 104

4th Clutch

Seal

INSTALL THE 15 SCREWS THAT ARE SHADED TO SECURE THE

TRANSMISSION RANGE SENSOR

05111

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4799655

98

TRANSMISSION RANGE SENSOR

SELECTOR PLATE

Figure 105

AUTOMATIC TRANSMISSION SERVICE GROUP

79

Technical Service Information

TRS/SOLENOID PACK

1. The TRS/Solenoid Pack is serviced only as a complete assembly, which is why we told you not to remove the screws on top that retain the cover plate.

2. However, if someone has not listened, we have provided you with an exploded view of the TRS/Solenoid Pack in Figures 105 and 106.

TRANSMISSION RANGE SENSOR AND PRESSURE SWITCH EXPLODED VIEW

The illustrations in Figures 105 and 106 have been provided as information only. We recommend that the TRS/Solenoid Pack NOT be disassembled as none of the internal parts are serviced seperately.

3000 5%

LEGEND FOR FIGURES 105 AND 106.

1. TRS/SOLENOID BODY COVER RETAINING SCREWS (6 REQ).

2. TRS/SOLENOID BODY COVER.

3. HYDRAULIC SWITCH RETURN SPRINGS (5 REQUIRED).

4. TRS/SOLENOID BODY AND 23 WAY CONNECTOR.

5. HYDRAULIC SWITCH COPPER CONTACT (5 REQUIRED).

6. HYDRAULIC SWITCH LIP SEAL (5 REQUIRED).

7. HYDRAULIC SWITCH COVER (5 REQUIRED).

8. TRS/SOLENOID BODY SPACER PLATE.

9. SOLENOID RETENTION SPRINGS (3 REQUIRED).

10. SOLENOID NEEDLE VALVE/SEAT ASSEMBLY (4 REQUIRED) LR/CC, OD, 2ND CLUT, 4TH CLUT SOLENOIDS.

11. SOLENOID NEEDLE VALVE/SEAT ASSEMBLY (2 REQUIRED) MULTI-SELECT AND UNDERDRIVE SOLENOIDS.

12. SOLENOID NEEDLE AND SEAT BODY.

13. SHIFT SOLENOID POLES (3 REQUIRED).

14. TRS/SOLENOID BODY SCREEN AND GASKET ASSEMBLY.

15. SCREEN/GASKET ASSEMBLY RETAINING SCREWS (2 REQ).

16. LINE PRESSURE SOLENOID SMALL "O" RING.

17. LINE PRESSURE SOLENOID LARGE "O" RING.

18. LINE PRESSURE SOLENOID WAVE WASHER.

19. LINE PRESSURE SOLENOID.

20. LINE PRESSURE SOLENOID RETAINING PINS (2 REQUIRED).

2

3000 5%

3

1

3

4

3000 5%

5

6 7

8

80

Figure 106

AUTOMATIC TRANSMISSION SERVICE GROUP

11

Technical Service Information

TRANSMISSION SOLENOID PACK EXPLODED VIEW

10

9

12

Side View

Showing

Proper Spring

Installation

14

13

16

17

20

18 19

15

Figure 107

AUTOMATIC TRANSMISSION SERVICE GROUP

81

Technical Service Information

1

2

3

TRANSMISSION

CASE ASSEMBLY

3

TRANSMISSION

CASE ASSEMBLY

1. SECOND CLUTCH STEEL PLATES (2 REQUIRED).

2. SECOND CLUTCH FRICTION PLATES (2 REQUIRED).

3. SECOND CLUTCH BACKING PLATE.

Figure 108

82

AUTOMATIC TRANSMISSION SERVICE GROUP

1. 2-4 CLUTCH RETAINER TAPERED SNAP RING (GOES IN CASE).

2. 2-4 CLUTCH RETAINER.

3. 2-4 CLUTCH RETAINER FLAT SNAP RING (GOES IN CASE).

Figure 109

Technical Service Information

FINAL TRANSMISSION ASSEMBLY

1. The 2nd clutch must be installed temporarily as this is the only way to gauge clutch clearance.

2. Install the 2nd clutch backing plate into the transmission case as shown in Figure 108.

3. Install the 2nd clutch pack that you are going to use, beginning with a lined plate and alternating with steel plates until you have installed 2 lined plates and 2 steel plates (See Figure 108).

4. Install the 2-4 clutch retainer flat snap ring into the transmission case as shown in Figure 109.

5. Install the 2-4 clutch retainer assembly into the transmission case with the oil feed holes toward the valve body area as shown in Figure 109.

6. Install the 2-4 clutch retainer tapered snap ring into the transmission case. Ensure that the snap ring open ends are located toward the valve body area. Refer to Figures 109 and 110.

7. Using a feeler gauge through rear case opening, measure the 2nd clutch pack clearance between the 2nd clutch backing plate and the trans case at 4 different points 90 degrees apart, as shown in Figure 110.

8. The average of these measurements is the 2nd clutch pack clearance. The 2nd clutch backing plate is selective to set proper clearance.

9. The correct 2nd clutch pack clearance should be

0.45-1.33 mm (.018"-.053").

10. Change the backing plate as necessary to set the proper clearance and re-measure the clearance to verify the selection.

11. Remove the 2-4 retainer and all the 2nd clutch components from the transmission case.

Continued on Page 84.

TAPERED SNAP RING

CHECKING 2ND CLUTCH CLEARANCE

FLAT SNAP RING

2ND CLUTCH

BACKING PLATE

Figure 110

AUTOMATIC TRANSMISSION SERVICE GROUP

83

Technical Service Information

FINAL TRANSMISSION ASSEMBLY (Cont'd)

12. Install the low/reverse clutch housing into the transmission case as shown in Figure 111. The clutch housing has one lug that is wider than all the rest to orient it in the case with the feed hole toward the valve body.

13. Install the tapered snap ring into the groove in the case just above the low/reverse housing and ensure that it is fully seated (See Figure 111).

14. Install the number 12 thrust bearing assembly onto the low/reverse clutch housing with the inside tabs facing down (See Figure 112).

15. Install the input internal ring gear assembly as shown in Figure 112 and ensure that the lugs are engaged onto the low roller outer race.

16. Air check the low/reverse clutch pack and also verify low roller clutch for correct operation.

17. Install input carrier/reverse internal ring gear as shown in Figure 113, by rotating into position, to engage the teeth on input internal ring gear.

18. Install the number 11 thrust bearing assembly into the input carrier in the direction shown in Figure 113.

Continued on Page 85.

1

2

1

2

1. LOW/REVERSE CLUTCH HOUSING "TAPERED" SNAP RING.

2. LOW/REVERSE CLUTCH HOUSING ASSEMBLY.

Figure 111

84

AUTOMATIC TRANSMISSION SERVICE GROUP

1. INPUT INTERNAL RING GEAR ASSEMBLY.

2. NUMBER 12 THRUST BEARING.

Figure 112

Technical Service Information

Number 10 bearing and Sun gear combinations

Bearing

thickness

.150"

Step on

sun gear

.142"

1

2

3

Bearing

thickness

.204"

Step on

sun gear

.085"

FINAL TRANSMISSION ASSEMBLY (Cont'd)

19. Install the input sun gear assembly, as shown in Figure 113, by rotating into position. Note: There are two Number 10 bearing and

Sun gear combinations. Both can be used as a set.

20. Install the number 10 thrust bearing assembly onto the reverse planetary carrier in direction shown in Figure 114, and retain with a small amount of TransJel®.

21. Install the reverse planetary carrier assembly in the transmission by rotating into position so as to engage the planet pinions and the carrier tabs into the input internal gear.

22. Install the reverse carrier/input ring gear flat snap ring into the groove in the input internal ring gear (See Figure 114).

Continued on Page 86.

1

2

Note: This bearing

has two

thicknesses

refer to Figure 113

3

1. INPUT SUN GEAR ASSEMBLY.

2. INPUT CARRIER/REVERSE INTERNAL RING GEAR ASSEMBLY.

3. NUMBER 11 THRUST BEARING.

Figure 113

AUTOMATIC TRANSMISSION SERVICE GROUP

1. REVERSE CARRIER/INPUT RING GEAR "FLAT" SNAP RING.

2. REVERSE PLANETARY CARRIER ASSEMBLY.

3. NUMBER 10 THRUST BEARING.

Figure 114

85

Technical Service Information

FINAL TRANSMISSION ASSEMBLY (Cont'd)

23. Install the number 9 thrust bearing onto to back side of the reaction carrier/reverse sun gear assembly, in the direction shown in Figure 115, and retain with a small amount of TransJel®.

24. Install the reaction carrier/reverse sun gear assembly, with bearing, into the transmission by rotating into position (See Figure 115).

25. Install the number 8 thrust bearing down inside of reaction carrier/reverse sun gear assembly in the direction shown in Figure 116.

26. Install the reaction sun gear in transmission by rotating into position (See Figure 116).

27. Install the number 7 thrust bearing into back side of the reaction internal gear, in direction shown in Figure 116, and retain with a small amount of TransJel®.

28. Install the reaction internal gear assembly into trans by rotating into position (See Figure 116).

29. Install rear selective plate on reaction ring gear with oil grooves facing down and engaged on tabs as shown in Figure 116.

30. Install the 2nd clutch backing plate into case as shown in Figure 117.

31. Install the 2nd clutch pack into case beginning with a lined plate and alternating with steels until you have installed 2 lined & 2 steel plates as shown n Figure 117.

32. Install the 2-4 clutch retainer flat snap ring into lower groove in the transmission case. Refer to Figure 118.

1

2

3

1

4

5

2

1. REACTION CARRIER/REVERSE SUN GEAR ASSEMBLY.

2. NUMBER 9 THRUST BEARING.

Figure 115 Figure 116

86

AUTOMATIC TRANSMISSION SERVICE GROUP

1. REAR SELECTIVE THRUST PLATE.

2. REACTION INTERNAL RING GEAR ASSEMBLY.

3. NUMBER 7 THRUST BEARING.

4. REACTION SUN GEAR.

Technical Service Information

33. Install the number six thrust bearing assembly onto the bottom of 2-4 clutch retainer in the direction shown in Figure 118, and retain with a small amount of TransJel®.

34. Install the 2-4 clutch retainer into the case as shown in Figure 118.

35. Install the 2-4 clutch retainer tapered snap ring in case with taper facing up (See Figure 118). Ensure snap ring openings face valve body.

Continued on Page 88.

1

2

1

2

3

4

3

4

5

1. SECOND CLUTCH STEEL PLATES (2 REQUIRED).

2. SECOND CLUTCH FRICTION PLATES (2 REQUIRED).

3. SECOND CLUTCH BACKING PLATE.

Figure 117 Figure 118

AUTOMATIC TRANSMISSION SERVICE GROUP

1. 2-4 CLUTCH RETAINER TAPERED SNAP RING (GOES IN CASE).

2. 2-4 CLUTCH RETAINER.

3. NUMBER 6 THRUST BEARING.

4. 2-4 CLUTCH RETAINER FLAT SNAP RING (GOES IN CASE).

87

Technical Service Information

NUMBER ONE

THRUST BEARING

DIAL INDICATOR

0

1010

2020

3030

4040

5050

0

INPUT CLUTCH

HOUSING ASSEMBLY

NUMBER FIVE

THRUST BEARING

(SELECTIVE)

88

Figure 119

AUTOMATIC TRANSMISSION SERVICE GROUP

AA

099

TITTJ243810187

P52119099AA 45RF

243810187P52119099AA

Figure 120

Technical Service Information

FINAL TRANSMISSION ASSEMBLY (Cont'd)

36. Install dial indicator on case and output shaft as shown in Figure 119. Zero the dial indicator and measure output shaft end play.

37. The correct transmission output shaft end-play should be 0.22-0.55 mm (.009"-.021").

38. Change the rear selective thrust plate that is shown in Figure 116 as necessary to achieve the correct end-play and re-measure to verify.

39. Air check both 2nd clutch and 4th clutch for proper operation.

40. Install the number 5 selective thrust bearing on reverse clutch hub as shown in Figure 120, and retain with a small amount of TransJel®.

41. Install the number 1 thrust bearing assembly with the flat side down, into the pocket of the input housing as shown in Figure 120.

2

42. Install input clutch housing assembly into the transmission case (See Figure 120). Ensure that input clutch assembly is fully seated by looking through the input speed sensor hole.

43. Install the pre-assembled pump assembly into the transmission case, as shown in Figure 121, and torque the six bolts to 28 Nm (250 in lbs).

44. Install dial indicator and measure input shaft end clearance as shown in Figure 122. Correct end-play is0.46-0.89 mm (.018"-.035").

45. Change the number 5 selective thrust bearing assembly and re-measure to verify selection.

NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft is pushed inward and the indicator zeroed, the first stop felt when the input shaft is pulled outward is the movement of the input shaft in the input clutch hub. This value should not be included in the end-play measurement and therefore must be recorded and subtracted from the total dial indicator reading.

1

4

6

0

1 7

2

9

1 9

2 3 3

8 5

C R

-

2

A

2

1

Continued on Page 90.

DIAL INDICATOR

0

1010

2020

3030

4040

5050

0

1. COMPLETE PUMP ASSEMBLY.

2. PUMP TO CASE RETAINING BOLTS (6 REQUIRED).

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 122Figure 121

89

Technical Service Information

FINAL TRANSMISSION ASSEMBLY (Cont'd)

46. Install the transmission front cover plate which is stamped aluminum, on early models, with molded inner and outer seals as shown in Figure 123. NOTE: 2007 & Up have changed.

The new version cover is steel and the pump seal is installed into the cover which eliminated snap ring 3.

47. Install the outer front cover plate snap ring to hold the front cover plate in the case as shown in Figure 123.

48. Install the inner front cover plate snap ring onto the oil pump assembly (See Figure 123).

2

3

49. Install the cooler filter by-pass valve into the trans case and torque to 11.3 Nm (100 in lb). Do Not over-torque! Refer to Figure 124.

50. Install cooler filter in transmission case using a filter wrench (See Figure 124).

51. Air pressure test all clutch components again at this time before valve body is installed using Figure 125 as a guide.

Continued on Page 92.

LATE 07 &UPEARLY

2

ALLUMINUM PUMP

COVER

4

6

1

7

9

1

9

2 3 3

8 5

C

R

-

2

A

1

STEEL PUMP

COVER RETAINS

FRONT SEAL

1. PUMP COVER PLATE (MOLDED SEALS).

2. PUMP COVER PLATE OUTER RETAINING SNAP RING.

3. PUMP COVER PLATE INNER RETAINING SNAP RING.

90

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 123

Technical Service Information

COOLER FILTER

BYPASS VALVE

COOLER FILTER

Low/Reverse

Clutch

2nd Clutch

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

Figure 124

AIR PRESSURE TESTS

4th Clutch

Overdrive

Clutch

Underdrive

Clutch

Figure 125

AUTOMATIC TRANSMISSION SERVICE GROUP

Reverse

Clutch

91

Technical Service Information

FINAL TRANSMISSION ASSEMBLY (Cont'd)

52. Install the pre-assembled valve body assembly as shown in Figure 126, using the 6 valve body to case bolts. Torque the valve body to case bolts to 12 Nm (105 in lb).

53. Use care when installing the valve body as the assembly has locating dowels that must line up with bores in case, and the 23 way connector seal must not be damaged.

54. Use the illustration in Figure 127 to identify the exact location of the valve body bolts.

55. Install a new primary bottom pan oil filter as shown in Figure 128.

56. Lubricate the oil filter seal before installing so as not to damage it as you install filter into the oil pump filter seal bore.

57. Torque the oil filter bolt to 4.5 Nm (40 in lb).

Continued on Page 94.

VALVE BODY

RETAINING BOLTS

(6 REQUIRED)

05111

1

AK

4799655

98

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

92

Figure 126

AUTOMATIC TRANSMISSION SERVICE GROUP

VALVE BODY

RETAINING BOLTS

Technical Service Information

05111

4799655

1

AK

98

VALVE BODY

RETAINING BOLTS

VALVE BODY

RETAINING BOLTS

OIL FILTER

RETAINING BOLT

Figure 127

05111

4799655

1

AK

98

PRIMARY

OIL FILTER

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

Figure 128

AUTOMATIC TRANSMISSION SERVICE GROUP

93

Technical Service Information

FINAL TRANSMISSION ASSEMBLY (Cont'd)

58. Apply a bead of RTV silicone to the bottom pan and install bottom pan on the transmission case, as shown in Figure 129.

59. Ensure that magnet is inside the oil pan before installation.

60. Install 15 bottom pan retaining bolts, as shown in Figure 129 and torque the pan bolts down to 12 Nm (105 in lb).

61. Turn transmission over on pan and install park gear and park gear retaining snap ring as shown in Figure 130.

BOTTOM OIL PAN RETAINING BOLTS

(15 REQUIRED)

62. Apply a bead of RTV silicone and install the extension housing onto the transmission case as shown in Figure 130.

63. Install 12 extension housing bolts/studs and, as shown in Figure 130, and torque bolts down to 54 Nm (40 ft lb).

64. Install input shaft speed sensor into case bore, as shown in Figure 131, and torque bolt down to 12 Nm (105 in lb).

65. Install output shaft speed sensor into case bore, as shown in Figure 131, and torque bolt down to 12 Nm (105 in lb).

Continued on Page 96.

BOTTOM OIL PAN RETAINING BOLTS

(15 REQUIRED)

94

05111

1

AK

4799655

98

AA

099

243810187P52119099AA

P52119099AA 45RF

TITTJ243810187

Figure 129

AUTOMATIC TRANSMISSION SERVICE GROUP

TITTJ243810187

P52119099AA 45RF

243810187P52119099AA

Technical Service Information

PARK GEAR

099

AA

PARK GEAR

SNAP RING

Figure 130

INPUT SPEED

SENSOR

AUTOMATIC TRANSMISSION SERVICE GROUP

TITTJ243810187

P52119099AA 45RF

243810187P52119099AA

Figure 131

099

AA

OUTPUT SPEED

SENSOR

95

Technical Service Information

FINAL TRANSMISSION ASSEMBLY (Cont'd)

66. Install a new dipstick tube seal into the case bore as shown in Figure 132.

67. Install line pressure sensor into case bore, as shown in Figure 132, and torque bolt down to 12 Nm (105 in lbs).

68. If removed, install and torque both cooler line fittings in case to 17.5 Nm (155 in lbs).

69. This concludes transmission final assembly.

DIPSTICK

TUBE SEAL

END-PLAY SPECIFICATIONS

Output Shaft End-Play ............ 0.22-0.55 mm (.009"-.021")

Input Shaft End-Play ............... 0.46-0.89 mm (.018"-.035")

2nd Clutch Clearance ........... 0.45-1.33 mm (.018"-.053")

4th Clutch Clearance ............ 0.77-1.39 mm (.030"-.055")

L/R Clutch Clearance ............ 1.00-1.74 mm (.039"-.069")

OD Clutch Clearance ............ 1.10-1.85 mm (.043"-.073")

UD Clutch Clearance ............. 0.84-1.54 mm (.033"-.061")

Reverse Clutch Clearance ..... 0.81-1.24 mm (.032"-.049")

ONLY RECOMMENDED FLUID

Mopar® ATF Plus 3 or 4, Type 7176

96

LINE PRESSURE

SENSOR

Figure 129

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

TORQUE SPECIFICATIONS

Cooler Line Fittings ........................................................................................................................ 17.5 Nm (155 in lbs)

Bottom Oil Pan Bolts ...................................................................................................................... 11.8 Nm (105 in lbs)

Main Oil Filter Screw ......................................................................................................................... 4.5 Nm (40 in lbs)

Cooler Return Filter .......................................................................................................................... 14 Nm (125 in lbs)

Oil Pump Assembly Bolts ............................................................................................................... 28.2 Nm (250 in lbs)

Oil Pump Body To Oil Pump Cover Screws ........................................................................................ 4.5 Nm (40 in lbs)

Oil Pump Spacer Plate To Pump Body Screws ................................................................................... 4.5 Nm (40 in lbs)

Pressure Test Port Plugs ...................................................................................................................... 5.1 Nm (45 in lbs)

Stator Support To Pump Body Screws ............................................................................................ 11.8 Nm (105 in lbs)

Transfer Plate to Valve Body Screws .................................................................................................. 4.5 Nm (40 in lbs)

TRS/Solenoid Pack To Transfer Plate Screws ....................................................................................... 5.7 Nm (50 in lbs)

Accumulator Cover To Valve Body Screws ....................................................................................... 4.5 Nm (40 in lbs)

Detent Spring Retaining Screw ......................................................................................................... 4.5 Nm (40 in lbs)

Input Speed Sensor Bolt ................................................................................................................ 11.8 Nm (105 in lbs)

Output Speed Sensor Bolt ............................................................................................................. 11.8 Nm (105 in lbs)

Line Pressure Sensor Bolt ............................................................................................................... 11.8 Nm (105 in lbs)

Extension Housing Bolts ...................................................................................................................... 54 Nm (40 ft lbs)

TRS Selector Plate To Valve Body Screw ............................................................................................ 4.5 Nm (40 in lbs)

Figure 130

25

Torx

20

Torx

A

15 mm

B C

L M

25

Torx25Torx25Torx

15 mm

D

30

Torx

N

BOLT IDENTIFICATION

30

Torx

E

F

A. SOLENOID BODY GASKET TO SOLENOID BODY (2 REQUIRED). B. TRS SELECTOR PLATE TO VALVE BODY (1 REQUIRED). C. ACCUMULATOR COVER TO VALVE BODY (7 REQUIRED). C. PUMP SPACER PLATE TO PUMP BODY (2 REQUIRED). D. OIL PUMP BODY TO OIL PUMP COVER (24 REQUIRED). E. TRANSFER PLATE TO VALVE BODY, SILVER COLOR (50 REQUIRED). E. TRS/SOLENOID PACK COVER BOLTS, GOLD COLOR (6 REQUIRED). F. STATOR SUPPORT TO PUMP BODY (5 REQUIRED). G. OIL PAN TO TRANSMISSION CASE (15 REQUIRED). H. INPUT, OUTPUT, LINE PRESSURE SENSORS TO CASE (3 REQUIRED). J. VALVE BODY TO TRANSMISSION CASE (6 REQUIRED). K. OIL PUMP TO TRANSMISSION CASE (6 REQUIRED). L. EXTENSION HOUSING TO TRANSMISSION CASE (10 REQUIRED). M. EXTENSION HOUSING TO TRANSMISSION CASE (2 REQUIRED). N. MANUAL SHAFT RETAINING BOLT (1 REQUIRED).

8 mm 8 mm 8 mm

G

H

J

Bolts Drawn Actual Size

10 mm

K

Figure 131

AUTOMATIC TRANSMISSION SERVICE GROUP

97

Technical Service Information

OIL PUMP ASSEMBLY EXPLODED VIEW

2

3

4

5

1

102

3

8

3

2

5

C

9

1

R

9

-

7

2

1

A

6

4

6

2

4

7

8

10

9

1. FRONT OIL PUMP CONVERTER SEAL.

2. PUMP BODY TO PUMP COVER RETAINING BOLTS (24 REQUIRED).

3. OIL PUMP BODY ASSEMBLY.

4. PUMP BODY TO PUMP COVER "HOLLOW" DOWELS (2 REQUIRED).

5. OIL PUMP DRIVE GEAR.

6. OIL PUMP DRIVEN GEARS.

7. OIL PUMP SHUTTLE VALVE.

8. OIL PUMP SPACER PLATE.

9. OIL PUMP SPACER PLATE RETAINING BOLTS (2 REQUIRED).

10. OIL PUMP COVER ASSEMBLY.

11. PUMP STATOR ASSEMBLY.

12. PUMP STATOR SEALING RINGS (5 REQUIRED) Note : Early Model pump depicted..

98

AUTOMATIC TRANSMISSION SERVICE GROUP

9

Figure 132

11

12

13

Technical Service Information

GEAR TRAIN COMPONENTS EXPLODED VIEW

16

1314151718

910

8

67

12

11

5

4

1. PARK GEAR RETAINING SNAP RING.

2. PARK GEAR ASSEMBLY.

3. NUMBER 12 THRUST BEARING.

4. INPUT INTERNAL RING GEAR.

5. INPUT PLANETARY CARRIER/REVERSE INTERNAL RING GEAR.

6. NUMBER 11 THRUST BEARING.

7. INPUT SUN GEAR.

8. NUMBER 10 THRUST BEARING.

9. REVERSE PLANETARY CARRIER ASSEMBLY.

3

10. REVERSE CARRIER/INPUT RING GEAR "FLAT" SNAP RING.

11. NUMBER 9 THRUST BEARING.

12. REACTION CARRIER/REVERSE SUN GEAR ASSEMBLY.

13. NUMBER 8 THRUST BEARING.

14. REACTION SUN GEAR.

15. NUMBER 7 THRUST BEARING.

16. REACTION INTERNAL RING GEAR ASSEMBLY.

17. SELECTIVE THRUST WASHER PLATE.

18. NUMBER 6 THRUST BEARING.

2

1

Figure 133

AUTOMATIC TRANSMISSION SERVICE GROUP

99

Technical Service Information

INPUT CLUTCH HOUSING COMPONENTS EXPLODED VIEW

9

2

1

3

6

4

5

4799090

87

18

34

19

35

37 38

20

21

22

23

24

100

36

Figure 134

AUTOMATIC TRANSMISSION SERVICE GROUP

Chrysler 45RFE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual