45 rfe dodge liberty

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45 rfe dodge liberty

  1. 1. OIL PUMP FRONT SEALREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 436OUTPUT SPEED SENSORDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 436OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 436REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 437TOW/HAUL OVERDRIVE SWITCHDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 437OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 437REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 438PISTONSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 438OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 438PLANETARY GEARTRAINDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 440OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 441DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 442CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 442INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 442ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 443SHIFT MECHANISMDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 444OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 444SOLENOID SWITCH VALVEDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 444OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 444SOLENOIDSDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 444OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 445TORQUE CONVERTERDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 445OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 449REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 451TRANSMISSION CONTROL RELAYDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 451OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 451TRANSMISSION RANGE SENSORDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 451OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 451TRANSMISSION SOLENOID/TRS ASSEMBLYDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 452OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 452REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 454TRANSMISSION TEMPERATURE SENSORDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 454OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 454VALVE BODYDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 454OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 454REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 457CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 459INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 460ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 461INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 463AUTOMATIC TRANSMISSION -45RFE/545RFEDESCRIPTIONThe 45RFE/545RFE automatic transmissions is asophisticated, multi-range, electronically controlledtransmission which combines optimized gear ratiosfor responsive performance, state of the art efficiencyfeatures and low NVH. Other features include driveradaptive shifting and three planetary gear sets toprovide wide ratio capability with precise ratio stepsfor optimum driveability. The three planetary gearsets also make available a unique alternate secondgear ratio. The primary 2nd gear ratio fits between1st and 3rd gears for normal through-gear accelera-tions. The alternate second gear ratio (2prime) allowssmoother 4-2 kickdowns at high speeds to provide2nd gear passing performance over a wider highwaycruising range.The hydraulic portion of the transmission consistsof the transmission fluid, fluid passages, hydraulicvalves, and various line pressure control components.The primary mechanical components of the trans-mission consist of the following:• Three multiple disc input clutches• Three multiple disc holding clutches• Five hydraulic accumulators• Three planetary gear sets• Dual Stage Hydraulic oil pump• Valve body• Solenoid packThe TCM is the “heart” or “brain” of the electroniccontrol system and relies on information from vari-ous direct and indirect inputs (sensors, switches, etc.)to determine driver demand and vehicle operatingconditions. With this information, the TCM can cal-culate and perform timely and quality shifts throughvarious output or control devices (solenoid pack,transmission control relay, etc.).21 - 350 AUTOMATIC TRANSMISSION - 45RFE/545RFE DR
  2. 2. TRANSMISSION IDENTIFICATIONTransmission identification numbers are stampedon the left side of the case just above the oil pansealing surface (Fig. 1). Refer to this informationwhen ordering replacement parts. A label is attachedto the transmission case above the stamped numbers.The label gives additional information which mayalso be necessary for identification purposes.GEAR RATIOSThe 45RFE gear ratios are:1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:12nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:12nd Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:13rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:14th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1GEAR RATIOSThe 545RFE gear ratios are:1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:12nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:12nd Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:13rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:14th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:15th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.67:1Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1OPERATIONThe 45RFE/545RFE offers full electronic control ofall automatic up and downshifts, and features real-time adaptive closed-loop shift and pressure control.Electronic shift and torque converter clutch controlshelp protect the transmission from damage due tohigh temperatures, which can occur under severeoperating conditions. By altering shift schedules, linepressure, and converter clutch control, these controlsreduce heat generation and increase transmissioncooling.To help reduce efficiency-robbing parasitic losses,the transmissions includes a dual-stage transmissionfluid pump with electronic output pressure control.Under most driving conditions, pump output pres-sure greatly exceeds that which is needed to keep theclutches applied. The 45RFE/545RFE pump-pressurecontrol system monitors input torque and adjusts thepump pressure accordingly. The primary stage of thepump works continuously; the second stage isbypassed when demand is low. The control systemalso monitors input and output speed and, if incipi-ent clutch slip is observed, the pressure control sole-noid duty cycle is varied, increasing pressure inproportion to demand.A high-travel torque converter damper assemblyallows earlier torque converter clutch engagement toreduce slippage. Needle-type thrust bearings reduceinternal friction. The 45RFE/545RFE is packaged ina one-piece die-cast aluminum case. To reduce NVH,the case has high lateral, vertical and torsional stiff-ness. It is also designed to maximize the benefit ofthe structural dust cover that connects the bottom ofthe bell housing to the engine bedplate, enhancingoverall power train stiffness. Dual filters protect thepump and other components. A pump return filter isadded to the customary main sump filter. Indepen-dent lubrication and cooler circuits assure amplepressure for normal transmission operation even ifthe cooler is obstructed or the fluid cannot flow dueto extremely low temperatures.The hydraulic control system design (without elec-tronic assist) provides the transmission with PARK,REVERSE, NEUTRAL, SECOND, and THIRD gears,based solely on driver shift lever selection. Thisdesign allows the vehicle to be driven (in “limp-in”mode) in the event of a electronic control system fail-ure, or a situation that the Transmission ControlModule (TCM) recognizes as potentially damaging tothe transmission.The TCM also performs certain self-diagnosticfunctions and provides comprehensive information(sensor data, DTC’s, etc.) which is helpful in properdiagnosis and repair. This information can be viewedwith the DRB௡ scan tool.Fig. 1 Transmission Part And Serial NumberLocation1 - IDENTIFICATION NUMBERS (STAMPED)DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 351AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  3. 3. DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - AUTOMATICTRANSMISSIONCAUTION: Before attempting any repair on a RFEautomatic transmission, check for Diagnostic Trou-ble Codes with the DRBா scan tool.Transmission malfunctions may be caused by thesegeneral conditions:• Poor engine performance• Improper adjustments• Hydraulic malfunctions• Mechanical malfunctions• Electronic malfunctionsDiagnosis of these problems should always beginby checking the easily accessible variables: fluid leveland condition, gearshift cable adjustment. Then per-form a road test to determine if the problem has beencorrected or if more diagnosis is necessary. If theproblem persists after the preliminary tests and cor-rections are completed, hydraulic pressure checksshould be performed.DIAGNOSIS AND TESTING - PRELIMINARYTwo basic procedures are required. One procedurefor vehicles that are drivable and an alternate proce-dure for disabled vehicles (will not back up or moveforward).VEHICLE IS DRIVABLE(1) Check for transmission fault codes using DRB௡scan tool.(2) Check fluid level and condition.(3) Adjust gearshift cable if complaint was basedon delayed, erratic, or harsh shifts.(4) Road test and note how transmission upshifts,downshifts, and engages.(5) Perform hydraulic pressure test if shift prob-lems were noted during road test.(6) Perform air-pressure test to check clutch oper-ation.VEHICLE IS DISABLED(1) Check fluid level and condition.(2) Check for broken or disconnected gearshiftcable.(3) Check for cracked, leaking cooler lines, or looseor missing pressure-port plugs.(4) Raise and support vehicle on safety stands,start engine, shift transmission into gear, and notefollowing:(a) If propeller shaft turns but wheels do not,problem is with differential or axle shafts.(b) If propeller shaft does not turn and transmis-sion is noisy, stop engine. Remove oil pan, andcheck for debris. If pan is clear, remove transmis-sion and check for damaged driveplate, converter,oil pump, or input shaft.(c) If propeller shaft does not turn and transmis-sion is not noisy, perform hydraulic-pressure test todetermine if problem is hydraulic or mechanical.DIAGNOSIS AND TESTING - ROAD TESTINGBefore road testing, be sure the fluid level and con-trol cable adjustments have been checked andadjusted if necessary. Verify that all diagnostic trou-ble codes have been resolved.Observe engine performance during the road test.A poorly tuned engine will not allow accurate analy-sis of transmission operation.Operate the transmission in all gear ranges. Checkfor shift variations and engine flare which indicatesslippage. Note if shifts are harsh, spongy, delayed,early, or if part throttle downshifts are sensitive.Slippage indicated by engine flare, usually meansclutch, overrunning clutch, or line pressure problems.A slipping clutch can often be determined by com-paring which internal units are applied in the vari-ous gear ranges. The Clutch Application chartsprovide a basis for analyzing road test results.21 - 352 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  4. 4. 45RFE CLUTCH APPLICATION CHARTSLP UD OD R 2C 4C L/R OVERRUNNINGP–PARK ONR–REVERSE ON ONN-NEUTRAL OND–OVERDRIVEFIRSTON ON* ONSECOND ON ONSECOND PRIME ON ONTHIRD ON ONFOURTH ON ONLIMP-IN ON ON2–FIRST ON ON* ONSECOND ON ONLIMP-IN ON ON1–LOW ON ON ON*L/R clutch is on only with the output shaft speed below 150 rpm.545RFE CLUTCH APPLICATION CHARTSLP UD OD R 2C 4C L/R OVERRUNNINGP–PARK ONR–REVERSE ON ONN-NEUTRAL OND–OVERDRIVEFIRSTON ON* ONSECOND ON ONSECOND PRIME ON ONTHIRD ON ONFOURTH ON ONFIFTH ON ONLIMP-IN ON ON2–FIRST ON ON* ONSECOND ON ONLIMP-IN ON ON1–LOW ON ON ON*L/R clutch is on only with the output shaft speed below 150 rpm.DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 353AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  5. 5. DIAGNOSIS AND TESTING - HYDRAULICPRESSURE TESTAn accurate tachometer and pressure test gaugesare required. Test Gauge C-3293-SP has a 300 psirange and is used at all locations where pressuresexceed 100 psi.Pressure Test Port LocationsOnly two pressure ports are supplied on the trans-mission case. The torque converter clutch apply andrelease ports are located on the right side of thetransmission case (Fig. 2).To determine the line pressure, there are two avail-able methods. The DRB௡ scan tool can be used toread line pressure from the line pressure sensor. Thesecond method is to install Line Pressure Adapter8259 (Fig. 4) into the transmission case and theninstall the pressure gauge and the original sensorinto the adapter. This will allow a comparison of theDRB௡ readings and the gauge reading to determinethe accuracy of the line pressure sensor. The DRB௡line pressure reading should match the gauge read-ing within ±10 psi.In order to access any other pressure tap locations,the transmission oil pan must be removed, the pres-sure port plugs removed and Valve Body PressureTap Adapter 8258-A (Fig. 5) installed. The extensionssupplied with Adapter 8258-A will allow the installa-tion of pressure gauges to the valve body. Refer to(Fig. 3) for correct pressure tap location identifica-tion.Fig. 2 Torque Converter Pressure Locations1 - TCC RELEASE2 - TO COOLER3 - TCC APPLY4 - FROM COOLER5 - LINE PRESSURE SENSORFig. 3 Pressure Tap LocationsFig. 4 Line Pressure Adapter 82591 - LINE PRESSURE SENSOR PORT2 - LINE PRESSURE SENSOR3 - TOOL 82594 - PRESSURE TAP21 - 354 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  6. 6. TEST PROCEDUREAll pressure readings should be taken with thetransmission fluid level full, transmission oil at thenormal operating temperature, and the engine at1500 rpm. Check the transmission for proper opera-tion in each gear position that is in question or if aspecific element is in question, check the pressurereadings in at least two gear positions that employthat element. Refer to the Hydraulic Schematics atthe rear of this section to determine the correct pres-sures for each element in a given gear position.NOTE: The 45RFE/545RFE utilizes closed loop con-trol of pump line pressure. The pressure readingsmay therefore vary greatly but should always followline pressure.Some common pressures that can be measured toevaluate pump and clutch performance are theupshift/downshift pressures, garage shift pressures,and TCC pressure. The upshift/downshift pressurefor all shifts are shown in UPSHIFT PRESSURESand DOWNSHIFT PRESSURES. In-gear maximumpressure for each gear position is shown in IN-GEARPRESSURES. The garage shift pressure when per-forming a N-R shift is 220 psi for 3.7L/4.7L equippedvehicles and 250 psi for 5.7L equipped vehicles. Thegarage shift pressure for the R-N shift is 120 psi. Thegarage shift pressure for the N-1 shift is 135 psi for3.7L/4.7L equipped vehicles and 165 psi for 5.7Lequipped vehicles. Torque converter lock-up pressureis 120 psi for 3.7L/4.7L equipped vehicles and 125 psifor 5.7L equipped vehicles.UPSHIFT PRESSURESENGINE 1-2 2-3 2prime-3 3-4 2prime-4 2-5 3-5 4-55.7L 150 125 125 135 135 135 135 1353.7L/4.7L 120 120 120 120 120 120 120 130DOWNSHIFT PRESSURESENGINE 5-4 5-3 5-2 4-3 4-2prime3-2 3-2prime2prime-1 2-1 3-15.7L 135 135 135 135 135 135 135 135 135 1353.7L/4.7L120 120 120 120 120 120 120 120 120 120IN-GEAR PRESSURESENGINE 1 2 2prime 3 4 5 NEUTRAL REVERSE5.7L 160 135 135 135 135 135 120 2503.7L/4.7L 135 120 120 120 120 120 120 220Fig. 5 Valve Body Pressure Tap Adapter 8258-A1 - RFE TRANSMISSION2 - TOOL 8258-ADR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 355AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  7. 7. DIAGNOSIS AND TESTING - AIR CHECKINGTRANSMISSION CLUTCH OPERATIONAir-pressure testing can be used to check transmis-sion clutch operation. The test can be conducted withthe transmission either in the vehicle or on the workbench, as a final check.Air-pressure testing requires that the oil pan andvalve body be removed from the transmission. Theclutch apply passages are shown in the Air PressureTest Passages graphic (Fig. 6).NOTE: The air supply which is used must be free ofmoisture and dirt. Use a pressure of 30 psi to testclutch operation.Apply air pressure at each port. If the clutch isfunctioning, a soft thump will be heard as the clutchis applied. The clutch application can also be felt bytouching the appropriate element while applying airpressure. As the air pressure is released, the clutchshould also release.DIAGNOSIS AND TESTING - CONVERTERHOUSING FLUID LEAKWhen diagnosing converter housing fluid leaks,two items must be established before repair.(1) Verify that a leak condition actually exists.(2) Determined the true source of the leak.Some suspected converter housing fluid leaks maynot be leaks at all. They may only be the result ofresidual fluid in the converter housing, or excessfluid spilled during factory fill or fill after repair.Converter housing leaks have several potentialsources. Through careful observation, a leak sourcecan be identified before removing the transmissionfor repair. Torque converter seal leaks tend to movealong the drive hub and onto the rear of the con-verter. Pump cover seal tend to run down the coverand the inside surface of the bellhousing.Some leaks, or suspected leaks, may be particu-larly difficult to locate. If necessary, a Mopar௡approved dye may be used to locate a leak.TORQUE CONVERTER LEAK POINTSPossible sources of converter leaks are:(1) Leaks at the weld joint around the outsidediameter weld (Fig. 7).(2) Leaks at the converter hub weld (Fig. 7).STANDARD PROCEDURE - ALUMINUMTHREAD REPAIRDamaged or worn threads in the aluminum trans-mission case and valve body can be repaired by theuse of Heli-Coils™, or equivalent. This repair con-sists of drilling out the worn-out damaged threads.Then tap the hole with a special Heli-Coil™ tap, orequivalent, and installing a Heli-Coil™ insert, orequivalent, into the hole. This brings the hole back toits original thread size.Heli-Coil™, or equivalent, tools and inserts arereadily available from most automotive parts suppli-ers.Fig. 6 Air Pressure Test Passages1 - LOW REVERSE CLUTCH2 - 4TH CLUTCH3 - 2ND CLUTCH4 - OVERDRIVE CLUTCH5 - UNDERDRIVE CLUTCH6 - REVERSE CLUTCHFig. 7 Torque Converter Assembly1 - TURBINE ASSEMBLY2 - STATOR3 - CONVERTER HUB4 - O-RING5 - IMPELLER ASSEMBLY6 - CONVERTER CLUTCH PISTON7 - TURBINE HUB21 - 356 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  8. 8. REMOVAL(1) Disconnect the negative battery cable.(2) Raise and support the vehicle(3) Remove any necessary skid plates. (Refer to 13- FRAMES & BUMPERS/FRAME/TRANSFER CASESKID PLATE - REMOVAL)(4) Mark propeller shaft and axle companionflanges for assembly alignment.(5) Remove the rear propeller shaft(6) Remove the front propeller shaft, if necessary.(7) Remove the engine to transmission collar (Fig.8).(8) Remove the exhaust support bracket from therear of the transmission.(9) Disconnect and lower or remove any necessaryexhaust components.(10) Remove the starter motor.(11) Rotate crankshaft in clockwise direction untilconverter bolts are accessible. Then remove bolts oneat a time. Rotate crankshaft with socket wrench ondampener bolt.(12) Disengage the output speed sensor connectorfrom the output speed sensor (Fig. 9).(13) Disengage the input speed sensor connectorfrom the input speed sensor (Fig. 10).(14) Disengage the transmission solenoid/TRSassembly connector from the transmission solenoid/TRS assembly (Fig. 11).(15) Disengage the line pressure sensor connectorfrom the line pressure sensor (Fig. 12).(16) Disconnect gearshift cable from transmissionmanual valve lever (Fig. 13).(17) Disconnect the transmission vent hose fromthe transmission.(18) Support rear of engine with safety stand orjack.(19) Raise transmission slightly with service jackto relieve load on crossmember and supports.(20) Remove bolts securing rear support and cush-ion to transmission and crossmember.(21) Remove transfer case, if necessary.(22) Disconnect transmission fluid cooler lines attransmission fittings and clips.(23) Remove all remaining converter housing bolts.(24) Carefully work transmission and torque con-verter assembly rearward off engine block dowels.Fig. 8 Transmission Collar1 - ENGINE2 - STRUCTURAL DUST COVER3 - TRANSMISSIONFig. 9 Disconnect Output Speed Sensor1 - TRANSMISSION2 - OUTPUT SPEED SENSORFig. 10 Disconnect Input Speed Sensor1 - TRANSMISSION2 - INPUT SPEED SENSORDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 357AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  9. 9. (25) Hold torque converter in place during trans-mission removal.(26) Lower transmission and remove (Fig. 14)assembly from under the vehicle.(27) To remove torque converter, carefully slidetorque converter out of the transmission.Fig. 11 Disconnect Transmission Solenoid/TRSAssembly1 - TRANSMISSION2 - TRANSMISSION SOLENOID/TRS ASSEMBLYFig. 12 Disconnect Line Pressure Sensor1 - TRANSMISSION2 - LINE PRESSURE SENSORFig. 13 Gearshift Cable at Transmission - RFE1 - GEARSHIFT CABLE2 - RFE TRANSMISSION3 - MANUAL LEVERFig. 14 Remove Transmission1 - ENGINE2 - TRANSMISSION21 - 358 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  10. 10. DISASSEMBLY(1) Drain fluid from transmission.(2) Clean exterior of transmission with suitablesolvent or pressure washer.(3) Remove the torque converter from the trans-mission.(4) Remove the manual shift lever (1) (Fig. 15)from the transmission.(5) Remove the input (3), output (1), and line pres-sure sensors (2) from the transmission case. (Fig. 16)(6) Inspect the ends of the sensors for debris,which may indicate the nature of the transmissionfailure.(7) Install Support Stand 8257 (1) onto the trans-mission case. (Fig. 17)(8) Using Adapter 8266-1 from End-Play Tool Set8266 (1) and Dial Indicator C-3339 (2), measure andrecord the input shaft end-play. (Fig. 18)Fig. 15 Remove the Manual Shaft Lever1 - MANUAL SHAFT LEVERFig. 16 Remove Input, Output, and Line PressureSensors1 - OUTPUT SPEED SENSOR2 - LINE PRESSURE SENSOR3 - INPUT SPEED SENSORFig. 17 Install Support Stand - Tool 82571 - TOOL 8257Fig. 18 Measure Input Shaft End Play1 - TOOL 82662 - TOOL C-3339DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 359AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  11. 11. NOTE: When measuring the input shaft end-play,two ؆stops؆ will be felt. When the input shaft ispushed inward and the dial indicator zeroed, thefirst ؆stop؆ felt when the input shaft is pulled out-ward is the movement of the input shaft in the inputclutch housing hub. This value should not beincluded in the end-play measured value and there-fore must be recorded and subtracted from the dialindicator reading.(9) Remove the bolts holding the transmissionextension/adapter housing to the transmission case.(10) Remove the extension/adapter housing fromthe transmission case.(11) Using Alignment Plate 8261 (1), Adapter8266-17 from End-Play Tool Set 8266 (2) and DialIndicator C-3339 (3), measure and record the outputshaft end-play. (Fig. 19)(12) Remove the bolts holding the transmission oilpan to the transmission case.(13) Remove the transmission oil pan from thetransmission case.(14) Remove the primary oil filter (1) and the oilcooler return filter (2). (Fig. 20)(15) Remove the cooler return filter bypass valve(3).(16) Remove the bolts (1) holding the valve body tothe transmission case. (Fig. 21)Fig. 19 Measure Output Shaft End Play1 - TOOL 82612 - TOOL 82663 - TOOL C-3339Fig. 20 Remove Primary Oil and Cooler Filters1 - PRIMARY OIL FILTER2 - COOLER RETURN FILTER3 - COOLER RETURN FILTER BYPASS VALVE4 - VALVE BODYFig. 21 Remove Valve Body Assembly1 - VALVE BODY TO CASE BOLT (6)21 - 360 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  12. 12. (17) Remove the valve body from the transmissioncase.(18) Remove the outer snap-ring (3) securing thetransmission front cover (2) into the transmissioncase. (Fig. 22)(19) Remove the inner snap-ring (1) securing thetransmission front cover to the oil pump. (Fig. 22)(20) Reaching through a case opening in the valvebody area with a long blunted tool, remove the trans-mission front cover from the transmission case.(21) Remove the bolts (1) holding the oil pump intothe transmission case. (Fig. 23)(22) Remove the oil pump (2). Hold inward on theinput shaft to prevent pulling the input clutchassembly with the oil pump. (Fig. 23)CAUTION: If the input shaft is not held during oilpump removal, the input clutch assembly willattempt to move forward with the oil pump and thenumbers 2, 3, or 4 bearings inside the input clutchassembly may become dislodged.(23) Remove the number 1 thrust bearing (4) fromthe input clutch assembly. (Fig. 24)(24) Remove the input clutch assembly (3) fromthe transmission case. (Fig. 24)(25) Remove the number 5 thrust bearing (1) andselective thrust plate (2) from the input clutchassembly (3) (Fig. 24), or the 4C clutch retainer/bulk-head.Fig. 22 Remove Transmission Front Cover1 - INNER SNAP-RING2 - TRANSMISSION FRONT COVER3 - OUTER SNAP-RINGFig. 23 Remove Oil Pump1 - OIL PUMP TO CASE BOLT (6)2 - OIL PUMPFig. 24 Remove Input Clutch Assembly1 - THRUST BEARING NUMBER 52 - THRUST PLATE (SELECT)3 - INPUT CLUTCH ASSEMBLY4 - THRUST BEARING NUMBER 1DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 361AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  13. 13. (26) Remove the 4C clutch retainer/bulkheadtapered snap-ring (1) from the transmission case.(Fig. 25)(27) Remove the 4C clutch retainer/bulkhead (2)from the transmission case. (Fig. 25)(28) Remove the front 2C clutch pack snap-ring (1)from the transmission case. (Fig. 26)(29) Remove the 2C clutch pack (2, 3, 4) from thetransmission case. (Fig. 26)(30) Remove the rear selective plate (6) and num-ber 6 thrust bearing (7) from the reaction annulus(8). (Fig. 27)(31) Remove the reaction annulus (8) from thereaction planetary carrier (3). (Fig. 27)(32) Remove the number 7 thrust bearing (5). (Fig.27)(33) Remove the reaction sun gear (4). (Fig. 27)(34) Remove the number 8 thrust bearing (1) fromthe reaction planetary carrier (3). (Fig. 27)(35) Remove the reaction planetary carrier (3)(Fig. 27). Note that this planetary gear set has threepinion gears.(36) Remove the number 9 thrust bearing (2) fromthe reverse planetary gear set. (Fig. 27)Fig. 25 Remove 4C Clutch Retainer/Bulkhead1 - SNAP-RING2 - 4C CLUTCH RETAINER/BULKHEADFig. 26 Remove 2C Clutch Pack1 - SNAP-RING2 - PLATE3 - DISC4 - REACTION PLATE21 - 362 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  14. 14. Fig. 27 Remove Reaction Annulus and Carrier1 - THRUST BEARING NUMBER 8 5 - THRUST BEARING NUMBER 72 - THRUST BEARING NUMBER 9 6 - THRUST PLATE (SELECT)3 - REACTION PLANETARY CARRIER 7 - THRUST BEARING NUMBER 64 - REACTION SUN GEAR 8 - REACTION ANNULUSDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 363AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  15. 15. (37) Remove the snap-ring (1) holding the parksprag gear onto the output shaft. (Fig. 28)(38) Remove the park sprag gear (1) from the out-put shaft. (Fig. 29)(39) Remove the input/reverse planetary assembly(1). (Fig. 30)(40) Remove the number 12 thrust bearing (3)from the input/reverse planetary assembly (1). (Fig.30)(41) Remove the snap-ring (2) holding the low/re-verse clutch retainer (1) into the transmission case.(Fig. 31)(42) Remove the low/reverse clutch retainer (1)from the transmission case. (Fig. 31)Fig. 28 Remove Park Sprag Snap-Ring1 - SNAP-RINGFig. 29 Remove Park Sprag Gear1 - PARK SPRAG GEARFig. 30 Remove Input/Reverse Planetary Assembly1 - INPUT/REVERSE PLANETARY ASSEMBLY2 - BEARING NUMBER 93 - BEARING NUMBER 12Fig. 31 Remove Low/Reverse Clutch Retainer1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY2 - SNAP-RING21 - 364 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  16. 16. (43) Remove the park rod (7) and e-clip. (Fig. 32)(44) Remove the park rod guide snap-ring (2). (Fig.32)(45) Remove the park rod guide (1). (Fig. 32)(46) Remove the park pawl pivot shaft (3), parkpawl (5), and spring (4). (Fig. 32)(47) Remove the manual selector shaft (6). (Fig. 32)(48) Remove the manual selector shaft seal.(49) Remove the dipstick tube seal.CLEANINGThe use of crocus cloth is permissible where neces-sary, providing it is used carefully. When used on shafts,or valves, use extreme care to avoid rounding off sharpedges. Sharp edges are vital as they prevent foreignmatter from getting between the valve and valve bore.Do not reuse oil seals, gaskets, seal rings, or O-ringsduring overhaul. Replace these parts as a matter ofcourse. Also do not reuse snap rings or E-clips that arebent or distorted. Replace these parts as well.Lubricate transmission parts with Mopar௡ ATF +4,Automatic Transmission Fluid, during overhaul andassembly. Use petroleum jelly, Mopar௡ Door Ease, orRu-Glyde to prelubricate seals, O-rings, and thrustwashers. Petroleum jelly can also be used to holdparts in place during reassembly.Clean the case in a solvent tank. Flush the casebores and fluid passages thoroughly with solvent.Dry the case and all fluid passages with compressedair. Be sure all solvent is removed from the case andthat all fluid passages are clear.NOTE: Do not use shop towels or rags to dry thecase (or any other transmission component) unlessthey are made from lint-free materials. Lint will stickto case surfaces and transmission components andcirculate throughout the transmission after assem-bly. A sufficient quantity of lint can block fluid pas-sages and interfere with valve body operation.INSPECTIONInspect the case for cracks, porous spots, wornbores, or damaged threads. Damaged threads can berepaired with Helicoil௡ thread inserts. However, thecase will have to be replaced if it exhibits any type ofdamage or wear.ASSEMBLYNOTE: Clean and inspect all components. Replaceany components which show evidence of excessivewear or scoring.(1) Install the cooler filter bypass valve. Torquethe bypass valve to specification. The valve uses atapered pipe thread and excessive torque can damagethe transmission case. Tighten the cooler filterbypass valve to 4.5 N·m (40 in.lbs.).(2) Install a new selector shaft seal (1) using SealInstaller 8253 (2). (Fig. 33)Fig. 32 Manual Shaft/Park Lock Components1 - GUIDE2 - SNAP-RING3 - SHAFT4 - SPRING5 - PARK PAWL6 - MANUAL SHAFT/LEVER7 - PARK RODFig. 33 Install Selector Shaft Seal1 - SEAL2 - TOOL 8253DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 365AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  17. 17. (3) Install the manual selector shaft and retainingscrew. Tighten the manual selector shaft retainingscrew to 28 N·m (250 in.lbs.).(4) Install the manual shift lever (1) (Fig. 34) ontothe manual selector shaft. Torque the retaining cross-bolt to 16 N·m (140 in.lbs.).(5) Install the park pawl (5), spring (4), and shaft(3). (Fig. 35)(6) Install the park rod (7) and e-clip. (Fig. 35)(7) Install the park rod guide (1) and snap-ring (2).(Fig. 35)(8) Install a new dipstick tube seal (2) using SealInstaller 8254 (1). (Fig. 36)NOTE: Before final assembly of transmission cen-terline, the 2C/4C clutch components should beinstalled into position and measured as follows:(9) Install the 2C reaction plate (4) into the trans-mission case. (Fig. 37)Fig. 34 Remove the Manual Shaft Lever1 - MANUAL SHAFT LEVERFig. 35 Manual Shaft/Park Lock Components1 - GUIDE2 - SNAP-RING3 - SHAFT4 - SPRING5 - PARK PAWL6 - MANUAL SHAFT/LEVER7 - PARK RODFig. 36 Install Dipstick Tube Seal Using Tool 82541 - TOOL 82542 - SEAL21 - 366 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  18. 18. (10) Install the 2C clutch pack (2, 3) into thetransmission case. (Fig. 37)(11) Install the flat 2C clutch snap-ring (1) into thetransmission case. (Fig. 37)(12) Install the 4C retainer/bulkhead (2) (Fig. 38)into the transmission case. Make sure that the oilfeed holes are pointing toward the valve body area.(13) Install the 4C retainer/bulkhead taperedsnap-ring (1) into the transmission case. Make surethat the open ends of the snap-ring are located in thecase opening toward the valve body area.(14) Using a feeler gauge through the opening inthe rear of the transmission case, measure the 2Cclutch pack clearance between the 2C reaction plateand the transmission case at four different points.The average of these measurements is the 2C clutchpack clearance. The correct clutch clearance is 0.455-1.335 mm (0.018-0.053 in.). The reaction plate is notselective. If the clutch pack clearance is not withinspecification, the reaction plate, all the friction discs,and steels must be replaced.(15) Remove the 4C retainer/bulkhead and all ofthe 2C clutch components from the transmissioncase.(16) Install the low/reverse clutch assembly (1)(Fig. 39). Make sure that the oil feed hole pointstoward the valve body area and that the bleed orificeis aligned with the notch in the rear of the transmis-sion case.(17) Install the snap-ring (2) (Fig. 39) to hold thelow/reverse clutch retainer into the transmissioncase. The snap-ring is tapered and must be installedwith the tapered side forward. Once installed, verifythat the snap-ring is fully seated in the snap-ringgroove.(18) Air check the low/reverse clutch and verifycorrect overrunning clutch operation.Fig. 37 Install 2C Clutch Pack1 - SNAP-RING2 - PLATE3 - DISC4 - REACTION PLATEFig. 38 Install 4C Clutch Retainer/Bulkhead1 - SNAP-RING2 - 4C CLUTCH RETAINER/BULKHEADFig. 39 Install Low/Reverse Clutch Retainer1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY2 - SNAP-RINGDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 367AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  19. 19. (19) Install the number 12 thrust bearing (3) overthe output shaft and against the rear planetary gearset. The flat side of the bearing goes toward the plan-etary gearset and the raised tabs on the inner raceshould face the rear of the transmission.(20) Install the reverse/input planetary assembly(1) through the low/reverse clutch assembly. (Fig. 40)(21) Install the park sprag gear (1) onto the outputshaft. (Fig. 41)(22) Install the snap-ring (1) to hold the parksprag onto the output shaft. (Fig. 42)(23) Install the 2C reaction plate (4) into thetransmission case. (Fig. 43)(24) Install the 2C clutch pack (2, 3, 4) into thetransmission case. (Fig. 43)(25) Install the number 8 thrust bearing (1) insidethe reaction carrier with the outer race against thereaction planetary carrier (3).(26) Install the reaction planetary gear set and thenumber 9 thrust bearing (2), with the inner raceagainst the reaction planetary carrier (3), into thetransmission case. (Fig. 44)Fig. 40 Install Input/Reverse Planetary Assembly1 - INPUT/REVERSE PLANETARY ASSEMBLY2 - BEARING NUMBER 93 - BEARING NUMBER 12Fig. 41 Install Park Sprag Gear1 - PARK SPRAG GEARFig. 42 Install Park Sprag Snap-Ring1 - SNAP-RINGFig. 43 Install 2C Clutch Pack1 - SNAP-RING2 - PLATE3 - DISC4 - REACTION PLATE21 - 368 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  20. 20. (27) Install the flat 2C clutch snap-ring into thetransmission case. (Fig. 43)(28) Install the reaction sun gear (4) into the reac-tion planetary gear set. Make sure the small shoul-der is facing the front of the transmission. (Fig. 44)(29) Install the number 7 thrust bearing (5) ontothe reaction sun gear (4) with the inner race againstthe sun gear. (Fig. 44)(30) Install the output shaft selective thrust plate(2) onto the reaction annulus with the oil grooves fac-ing the annulus gear and the lugs (1) and notchesaligned as shown. (Fig. 45)(31) Install the number 6 thrust bearing (7)against the output shaft selective thrust plate (6)with the flat side against the thrust plate (Fig. 44)and the raised tabs on the inner race facing the frontof the transmission.(32) Install the reaction annulus (8) into the reac-tion planetary gear set. (Fig. 44)(33) Install the 4C retainer/bulkhead (2) into thetransmission case. Make sure that the oil feed holesare pointing toward the valve body area. Rotate thereaction annulus during the installation of the 4Cretainer/bulkhead to ease installation.(34) Install the 4C retainer/bulkhead taperedsnap-ring (1) into the transmission case (Fig. 46)with the taper toward the front of the case. Makesure that the open ends of the snap-ring are locatedin the case opening toward the valve body area.(35) Air check the 2C and 4C clutch operation.(36) Using Alignment Plate 8261 (1), Adapter8266-17 from End-Play Tool Set 8266 (2) and DialIndicator C-3339 (3), measure (Fig. 47) and recordthe output shaft end-play. The correct output shaftend-play is 0.22-0.55 mm (0.009-0.021 in.). Adjust asnecessary. Install the chosen output shaft selectivethrust plate and re-measure end-play to verify selec-tion.Fig. 44 Install Reaction Annulus and Carrier1 - THRUST BEARING NUMBER 8 5 - THRUST BEARING NUMBER 72 - THRUST BEARING NUMBER 9 6 - THRUST PLATE (SELECT)3 - REACTION PLANETARY CARRIER 7 - THRUST BEARING NUMBER 64 - REACTION SUN GEAR 8 - REACTION ANNULUSDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 369AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  21. 21. (37) Apply a bead of RTV silicone and install theextension/adapter housing onto the transmissioncase.(38) Install and torque the bolts to hold the exten-sion/adapter housing onto the transmission case. Thecorrect torque is 54 N·m (40 ft.lbs.).(39) Install the number 5 thrust bearing (1) (Fig.48) and selective thrust plate (2) onto the 4C retain-er/bulkhead. Be sure that the outer race of the bear-ing is against the thrust plate.(40) Install the input clutch assembly (3) (Fig. 48)into the transmission case. Make sure that the inputclutch assembly is fully installed by performing avisual inspection through the input speed sensorhole. If the tone wheel teeth on the input clutchassembly are centered in the hole, the assembly isfully installed.(41) Install the number 1 thrust bearing (4) withthe outer race up in the pocket of the input clutchassembly. (Fig. 48)Fig. 45 Thrust Plate Alignment1 - LOCATING LUG (3)2 - THRUST PLATEFig. 46 Install 4C Clutch Retainer/Bulkhead1 - SNAP-RING2 - 4C CLUTCH RETAINER/BULKHEADFig. 47 Measure Output Shaft End Play1 - TOOL 82612 - TOOL 82663 - TOOL C-3339Fig. 48 Install Input Clutch Assembly1 - THRUST BEARING NUMBER 52 - THRUST PLATE (SELECT)3 - INPUT CLUTCH ASSEMBLY4 - THRUST BEARING NUMBER 121 - 370 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  22. 22. (42) Install the oil pump (2) into the transmissioncase. (Fig. 49)(43) Install the bolts (1) to hold the oil pump intothe transmission case. Tighten the oil pump bolts to28 N·m (250 in.lbs.).(44) Using Adapter 8266-1 from End-Play Tool Set8266 (1) and Dial Indicator C-3339 (2), measure (Fig.50) and record the input shaft end-play. The correctend-play is 0.46-0.89 mm (0.018-0.035 in.). Adjust asnecessary. Install the chosen thrust plate on thenumber 5 thrust bearing and re-measure end-play toverify selection.NOTE: When measuring the input shaft end-play,two ؆stops؆ will be felt. When the input shaft ispushed inward and the dial indicator zeroed, thefirst ؆stop؆ felt when the input shaft is pulled out-ward is the movement of the input shaft in the inputclutch housing hub. This value should not beincluded in the end-play measured value and there-fore must be recorded and subtracted from the dialindicator reading.(45) Install the transmission front cover (2) intothe transmission case. (Fig. 51)(46) Install the outer snap-ring (3) to hold thetransmission front cover (2) into the transmissioncase. (Fig. 51)(47) Partially install the inner transmission frontcover snap-ring (1) onto the oil pump. (Fig. 51)(48) Using Installer 8255 (1), install the innertransmission front cover snap-ring (2) the remainderof the way onto the oil pump. (Fig. 52)(49) Install the valve body. Verify that the pin onthe manual lever has properly engaged the TRSselector plate. Tighten the valve body to transmissioncase bolts (1) (Fig. 53) to 12 N·m (105 in.lbs.).CAUTION: The primary oil filter seal MUST be fullyinstalled flush against the oil pump body. DO NOTinstall the seal onto the filter neck and attempt toinstall the filter and seal as an assembly. Damage tothe transmission will result.Fig. 49 Install Oil Pump1 - OIL PUMP TO CASE BOLT (6)2 - OIL PUMPFig. 50 Measure Input Shaft End Play1 - TOOL 82662 - TOOL C-3339Fig. 51 Install the Transmission Front Cover1 - INNER SNAP-RING2 - TRANSMISSION FRONT COVER3 - OUTER SNAP-RINGDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 371AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  23. 23. (50) Install a new primary oil filter seal in the oilpump inlet bore. Seat the seal in the bore with thebutt end of a hammer, or other suitable tool.(51) Install the primary oil filter (1) (Fig. 54) andthe oil cooler return filter (2). Tighten the screw tohold the primary oil filter to the valve body to 4.5N·m (40 in.lbs.). Using Oil Filter Wrench 8321,tighten the cooler return oil filter to the transmissioncase to 14 N·m (125 in.lbs.).(52) Apply RTV silicone to the oil pan and installthe transmission oil pan. Tighten the bolts to 12 N·m(105 in.lbs.).(53) Install the input (3), output (1), and line pres-sure sensors (2) (Fig. 55). Tighten the bolts to 12 N·m(105 in.lbs.).INSTALLATION(1) Check torque converter hub and hub drive flatsfor sharp edges burrs, scratches, or nicks. Polish thehub and flats with 320/400 grit paper and crocuscloth if necessary. Verify that the converter hubo-ring is properly installed and is free of any debris.The hub must be smooth to avoid damaging pumpseal at installation.Fig. 52 Seat Snap-Ring Using Tool 82551 - TOOL 82552 - SNAP-RINGFig. 53 Install Valve Body Assembly1 - VALVE BODY TO CASE BOLT (6)Fig. 54 Install Primary Oil and Cooler Filters1 - PRIMARY OIL FILTER2 - COOLER RETURN FILTER3 - COOLER RETURN FILTER BYPASS VALVE4 - VALVE BODYFig. 55 Install Input, Output, and Line PressureSensors1 - OUTPUT SPEED SENSOR2 - LINE PRESSURE SENSOR3 - INPUT SPEED SENSOR21 - 372 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  24. 24. (2) If a replacement transmission is beinginstalled, transfer any components necessary, such asthe manual shift lever and shift cable bracket, fromthe original transmission onto the replacement trans-mission.(3) Lubricate oil pump seal lip with transmissionfluid.(4) Align converter and oil pump.(5) Carefully insert converter in oil pump. Thenrotate converter back and forth until fully seated inpump gears.(6) Check converter seating with steel scale andstraightedge (Fig. 56). Surface of converter lugsshould be at least 13mm (1/2 in.) to rear of straight-edge when converter is fully seated.(7) Temporarily secure converter with C-clamp.(8) Position transmission on jack and secure itwith chains.(9) Check condition of converter driveplate.Replace the plate if cracked, distorted or damaged.Also be sure transmission dowel pins are seatedin engine block and protrude far enough tohold transmission in alignment.(10) Apply a light coating of Mopar௡ High TempGrease to the torque converter hub pocket in the rearpocket of the engine’s crankshaft.(11) Raise transmission (Fig. 57) and align thetorque converter with the drive plate and transmis-sion converter housing with the engine block.(12) Move transmission forward. Then raise, loweror tilt transmission to align the converter housingwith engine block dowels.(13) Carefully work transmission forward and overengine block dowels until converter hub is seated incrankshaft. Verify that no wires, or the transmissionvent hose, have become trapped between the engineblock and the transmission.(14) Install two bolts to attach the transmission tothe engine.(15) Install remaining torque converter housing toengine bolts. Tighten to 68 N·m (50 ft.lbs.).(16) Install transfer case, if equipped. Tightentransfer case nuts to 35 N·m (26 ft.lbs.).(17) Install rear support to transmission. Tightenbolts to 47 N·m (35 ft.lbs.).(18) Lower transmission onto crossmember andinstall bolts attaching transmission mount to cross-member. Tighten clevis bracket to crossmember boltsto 47 N·m (35 ft.lbs.). Tighten the clevis bracket torear support bolt to 68 N·m (50 ft.lbs.).(19) Remove engine support fixture.(20) Connect gearshift cable to transmission.(21) Connect wires to solenoid and pressure switchassembly (Fig. 58) connector, input (Fig. 59) and out-put (Fig. 60) speed sensors, and line pressure sensor(Fig. 61). Be sure transmission harnesses are prop-erly routed.CAUTION: It is essential that correct length bolts beused to attach the converter to the driveplate. Boltsthat are too long will damage the clutch surfaceinside the converter.(22) Install torque converter-to-driveplate bolts.Tighten bolts to 31 N·m (270 in. lbs.).(23) Install starter motor and cooler line bracket.(24) Connect cooler lines to transmission.(25) Install transmission fill tube.(26) Install exhaust components, if necessary.Fig. 56 Checking Torque Converter Seating - Typical1 - SCALE2 - STRAIGHTEDGEFig. 57 Install Transmission1 - ENGINE2 - TRANSMISSIONDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 373AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  25. 25. (27) Install the structural dust cover (Fig. 62)(Refer to 9 - ENGINE/ENGINE BLOCK/STRUC-TURAL COVER - INSTALLATION) onto the trans-mission and the engine.(28) Align and connect propeller shaft(s).(29) Adjust gearshift cable if necessary.(30) Install any skid plates removed previously.(Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - INSTALLATION)(31) Lower vehicle.(32) Fill transmission with Mopar௡ ATF +4, Auto-matic Transmission Fluid.Fig. 62 Transmission Collar1 - ENGINE2 - STRUCTURAL DUST COVER3 - TRANSMISSIONFig. 58 Connect Transmission Solenoid1 - TRANSMISSION2 - TRANSMISSION SOLENOID/TRS ASSEMBLYFig. 59 Connect Input Speed Sensor1 - TRANSMISSION2 - INPUT SPEED SENSORFig. 60 Connect Output Speed Sensor1 - TRANSMISSION2 - OUTPUT SPEED SENSORFig. 61 Connect Line Pressure Sensor1 - TRANSMISSION2 - LINE PRESSURE SENSOR21 - 374 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  26. 26. SCHEMATICS AND DIAGRAMSHYDRAULIC SCHEMATICSHYDRAULICFLOWINPARK/NEUTRALDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 375AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  27. 27. HYDRAULICFLOWINNEUTRALOVER8MPH21 - 376 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  28. 28. HYDRAULICFLOWINREVERSEDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 377AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  29. 29. HYDRAULICFLOWINREVERSEBLOCK21 - 378 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  30. 30. HYDRAULICFLOWINFIRSTGEAR(FROMNOROD)DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 379AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  31. 31. HYDRAULICFLOWINFIRSTGEAR(AFTERLAUNCHFROMREST)21 - 380 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  32. 32. HYDRAULICFLOWINFIRSTGEAR(FROMK/D)DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 381AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  33. 33. HYDRAULICFLOWINSECONDGEAR21 - 382 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  34. 34. HYDRAULICFLOWINSECONDGEAREMCCDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 383AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  35. 35. HYDRAULICFLOWINSECONDPRIMEGEAR21 - 384 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  36. 36. HYDRAULICFLOWINSECONDPRIMEGEAREMCCDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 385AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  37. 37. HYDRAULICFLOWINDIRECTGEAR21 - 386 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  38. 38. HYDRAULICFLOWINDIRECTGEAR(FAILSAFE)DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 387AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  39. 39. HYDRAULICFLOWINDIRECTGEAREMCC21 - 388 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  40. 40. HYDRAULICFLOWINFOURTHDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 389AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  41. 41. HYDRAULICFLOWINFOURTHEMCC21 - 390 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  42. 42. HYDRAULICFLOWINFIFTHDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 391AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  43. 43. HYDRAULICFLOWINFIFTHEMCC21 - 392 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  44. 44. HYDRAULICFLOWINMANUALLOWORAUTOSTICK1STDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 393AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  45. 45. HYDRAULICFLOWINMANUALSECOND21 - 394 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  46. 46. HYDRAULICFLOWINMANUALSECOND(FAILSAFE)DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 395AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  47. 47. SPECIFICATIONSTRANSMISSIONGENERALComponent Metric InchOutput Shaft End Play 0.22-0.55mm0.009-0.021in.Input Shaft End Play 0.46-0.89mm0.018-0.035in.2C Clutch PackClearance0.455-1.335mm0.018-0.053in.4C Clutch PackClearance0.770-1.390mm0.030-0.055in.L/R Clutch PackClearance1.00-1.74mm0.039-0.069in.OD Clutch PackClearance1.103-1.856mm0.043-0.073in.Component Metric InchUD Clutch PackClearance0.84-1.54mm0.033-0.061in.Reverse Clutch PackClearance0.81-1.24mm0.032-0.049in.Recommended fluid Moparா ATF +4GEAR RATIOS1ST 3.00:12ND 1.67:12ND Prime 1.50:13RD 1.0:14TH 0.75:15TH 0.67:1REVERSE 3.00:1TORQUE SPECIFICATIONSDESCRIPTION N·m Ft. Lbs. In. Lbs.Fitting, cooler line at trans 17.5 - 155Bolt, torque convertor 31 23 -Bolt/nut, crossmember 68 50 -Bolt, driveplate to crankshaft 75 55 -Bolt, oil pan 11.8 - 105Screw, primary fluid filter 4.5 - 40Bolt, oil pump 28.2 - 250Bolt, oil pump body to cover 4.5 - 40Screw, plate to oil pump body 4.5 - 40Bolt, valve body to case 11.8 - 105Plug, pressure test port 5.1 - 45Bolt, reaction shaft support 11.8 - 105Screw, valve body to transfer plate 5.6 - 50Screw, solenoid module to transfer plate 5.7 - 50Screw, accumulator cover 7 - 60Screw, detent spring 4.5 - 40Bolt, input speed sensor 11.8 - 105Bolt, output speed sensor 11.8 - 105Bolt, line pressure sensor 11.8 - 105Bolt, extension housing 54 40 -Valve, cooler return filter bypass 4.5 - 40Screw, manual valve cam retaining 4.5 - 40Bolt, manual lever 28.2 - 25021 - 396 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  48. 48. SPECIAL TOOLSRFE TRANSMISSIONGauge, Oil Pressure - C-3292Gauge, Oil Pressure - C-3293SPDial Indicator - C-3339Installer, Seal - C-3860-ACompressor, Spring - 8249Compressor, Spring - 8250Compressor, Spring - 8251Installer, Piston - 8252DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 397AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  49. 49. Installer, Seal - 8253Installer, Seal - 8254Installer, Snap-ring - 8255Stand, Support - 8257Adapter, Pressure Tap - 8258-AAdapter, Line Pressure - 8259Fixture, Input Clutch Pressure - 8260Plate, Alignment - 826121 - 398 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRAUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  50. 50. End Play Set - 8266Compressor, Spring - 8285Installer, Bearing - 8320Wrench, Filter - 8321Installer, Piston - 8504DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 399AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
  51. 51. RETAINER/BULKHEAD-4CDISASSEMBLY(1) Remove the 2C piston Belleville spring snap-ring (6) from the 4C retainer /bulkhead (13). (Fig. 63)(2) Remove the 2C piston Belleville spring (5) fromthe retainer/bulkhead (13). (Fig. 63)(3) Remove the 2C piston (2) from the retainer/bulkhead (13). Use 20 psi of air pressure to removethe piston if necessary.(4) Remove the 4C clutch snap-ring (7) from theretainer/bulkhead (13). (Fig. 63)(5) Remove the 4C clutch pack (3, 4, 8) from theretainer/bulkhead (13). (Fig. 63)(6) Using Spring Compressor 8250 (2) (Fig. 64)and a suitable shop press (1), compress the 4C pistonreturn spring (10) and remove the snap-ring (9). (Fig.63)(7) Remove the 4C piston return spring (10) (Fig.63) and piston (12) from the retainer/bulkhead (13).Use 20 psi of air pressure to remove the piston if nec-essary.Fig. 63 4C Retainer/Bulkhead Components1 - SEAL 8 - REACTION PLATE2 - 2C PISTON 9 - SNAP-RING3 - PLATE 10 - RETURN SPRING4 - DISC 11 - SEAL5 - 2C BELLEVILLE SPRING 12 - 4C PISTON6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD7 - SNAP-RING (SELECT)21 - 400 AUTOMATIC TRANSMISSION - 45RFE/545RFE DR
  52. 52. ASSEMBLYNOTE: Clean and inspect all components. Replaceany components which show evidence of excessivewear or scoring.(1) Install new seals (1, 11) on the 2C and 4C pis-tons. (Fig. 65)(2) Lubricate all seals with Mopar௡ ATF +4 priorto installation.(3) Install the 4C piston (12) into the 4C retainer/bulkhead (13). (Fig. 65)(4) Position the 4C piston return spring (10) ontothe 4C piston (12).(5) Using Spring Compressor 8250 (2) and a suit-able shop press (1), compress the 4C piston returnspring and install the snap-ring. (Fig. 66)(6) Assemble and install the 4C clutch pack (3, 4)into the retainer/bulkhead (13) (Fig. 65) with thesteel separator plate against the piston.(7) Install the 4C reaction plate (8) (Fig. 65) andsnap-ring (7) into the retainer/bulkhead (13). The 4Creaction plate is non-directional.(8) Measure the 4C clutch clearance. The correctclutch clearance is 0.77-1.39 mm (0.030-0.055 in.).The snap-ring (7) is selectable. Install the chosensnap-ring and re-measure to verify the selection.(9) Install the 2C piston (2) into the retainer/bulk-head (13). (Fig. 65)(10) Position the 2C Belleville spring (5) onto the2C piston (2).(11) Position the 2C Belleville spring snap-ring (6)onto the 2C Belleville spring (5). (Fig. 65)Fig. 64 Compress 4C Piston Return Spring UsingTool 82501 - PRESS2 - TOOL 8250DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 401RETAINER/BULKHEAD-4C (Continued)
  53. 53. Fig. 65 4C Retainer/Bulkhead Components1 - SEAL 8 - REACTION PLATE2 - 2C PISTON 9 - SNAP-RING3 - PLATE 10 - RETURN SPRING4 - DISC 11 - SEAL5 - 2C BELLEVILLE SPRING 12 - 4C PISTON6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD7 - SNAP-RING (SELECT)21 - 402 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRRETAINER/BULKHEAD-4C (Continued)
  54. 54. (12) Using Spring Compressor 8249 (2) (Fig. 67)and a suitable shop press (1), compress the Bellevillespring (5) until the snap-ring (6) is engaged with thesnap-ring groove in the retainer/bulkhead.ADAPTER HOUSING SEALREMOVAL(1) Remove the transfer case from the transmis-sion.(2) Using a screw mounted on a slide hammer,remove the adapter housing seal.INSTALLATION(1) Clean the adapter seal bore in the adapterhousing of any residue or particles remaining fromthe original seal.(2) Install new oil seal in the adapter housingusing Seal Installer C-3860-A (1) (Fig. 68). A properlyinstalled seal is flush to the face of the seal bore.(3) Install the transfer case onto the transmission.Fig. 66 Compress 4C Piston Return Spring UsingTool 82501 - PRESS2 - TOOL 8250Fig. 67 Compress 2C Belleville Spring Using Tool82491 - PRESS2 - TOOL 8249Fig. 68 Adapter Housing Seal Installation1 - TOOL C-3860-ADR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 403RETAINER/BULKHEAD-4C (Continued)
  55. 55. BRAKE TRANSMISSION SHIFTINTERLOCK SYSTEMDESCRIPTIONThe Brake Transmission Shifter Interlock (BTSI)(Fig. 69), is a solenoid operated system. It consists ofa solenoid permanently mounted on the gearshiftcable.OPERATIONThe system locks the shifter into the PARK posi-tion. The interlock system is engaged whenever theignition switch is in the LOCK or ACCESSORY posi-tion. An additional electrically activated feature willprevent shifting out of the PARK position unless thebrake pedal is depressed approximately one-half aninch. A magnetic holding device in line with the parklock cable is energized when the ignition is in theRUN position. When the key is in the RUN positionand the brake pedal is depressed, the shifter isunlocked and will move into any position. The inter-lock system also prevents the ignition switch frombeing turned to the LOCK or ACCESSORY position,unless the shifter is fully locked into the PARK posi-tion.DIAGNOSIS AND TESTING - BRAKETRANSMISSION SHIFT INTERLOCK(1) Verify that the key can only be removed in thePARK position.(2) When the shift lever is in PARK And the shifthandle pushbutton is in the “OUT” position, the igni-tion key cylinder should rotate freely from OFF toLOCK. When the shifter is in any other gear or neu-tral position, the ignition key cylinder should notrotate to the LOCK position.(3) Shifting out of PARK should not be possiblewhen the ignition key cylinder is in the OFF posi-tion.(4) Shifting out of PARK should not be possiblewhile applying normal pushbutton force and ignitionkey cylinder is in the RUN or START positionsunless the foot brake pedal is depressed approxi-mately 1/2 inch (12mm).(5) Shifting out of PARK should not be possiblewhen the ignition key cylinder is in the ACCESSORYor LOCK positions.(6) Shifting between any gears, NEUTRAL or intoPARK may be done without depressing foot brakepedal with ignition switch in RUN or START posi-tions.ADJUSTMENTS - BRAKE TRANSMISSIONSHIFT INTERLOCKCorrect cable adjustment is important to properinterlock operation. The gearshift cable must be cor-rectly adjusted in order to shift out of PARK.ADJUSTMENT PROCEDURE(1) Remove the steering column trim as necessaryfor access to the brake transmission shift interlock.(2) Shift the transmission into the PARK position.(3) Pull upward on both the BTSI lock tab (4) andthe gearshift cable lock tab (3). (Fig. 70)(4) Verify that the shift lever is in the PARK posi-tion.Fig. 69 Brake Transmission Interlock Mechanism1 - STEERING COLUMN2 - GEARSHIFT CABLE3 - GEARSHIFT CABLE LOCK TAB4 - BTSI SOLENOID LOCK TAB5 - BTSI CONNECTORFig. 70 Brake Transmission Interlock Mechanism1 - STEERING COLUMN2 - GEARSHIFT CABLE3 - GEARSHIFT CABLE LOCK TAB4 - BTSI SOLENOID LOCK TAB5 - BTSI CONNECTOR21 - 404 AUTOMATIC TRANSMISSION - 45RFE/545RFE DR
  56. 56. (5) Verify positive engagement of the transmissionpark lock by attempting to rotate the propeller shaft.The shaft will not rotate when the park lock isengaged.(6) Turn ignition switch to LOCK position. Besure ignition key cylinder is in the LOCK posi-tion. Cable will not adjust correctly in anyother position.(7) Ensure that the cable is free to self-adjust bypushing cable rearward and releasing.(8) Push the gearshift cable lock tab (3) down untilit snaps in place.(9) Locate the BTSI alignment hole in the bottomof the BTSI mechanism between the BTSI lock taband the BTSI connector.(10) Move the BTSI assembly up or down on thegearshift cable until an appropriate size drill bit canbe inserted into the alignment hole and through theassembly.(11) Push the BTSI lock tab (4) down until it snapsinto place and remove the drill bit.(12) Install any steering column trim previouslyremoved.BTSI FUNCTION CHECK(1) Verify removal of ignition key allowed in PARKposition only.(2) When the shift lever is in PARK, the ignitionkey cylinder should rotate freely from off to lock.When the shifter is in any other position, the ignitionkey should not rotate from off to lock.(3) Shifting out of PARK should be possible whenthe ignition key cylinder is in the off position.(4) Shifting out of PARK should not be possiblewhile applying normal force, and ignition key cylin-der is in the run or start positions, unless the footbrake pedal is depressed approximately 1/2 inch(12mm).(5) Shifting out of PARK should not be possiblewhen the ignition key cylinder is in the accessory orlock position.(6) Shifting between any gear and NEUTRAL, orPARK, may be done without depressing foot brakewith ignition switch in run or start positions.(7) Engine starts must be possible with shifterlever in PARK or NEUTRAL positions only. Enginestarts must not be possible in any position other thanPARK or NEUTRAL.(8) With shifter lever in the:• PARK position - Apply upward force on the shiftarm and remove pressure. Engine starts must bepossible.• PARK position - Apply downward force on theshift arm and remove pressure. Engine starts mustbe possible.• NEUTRAL position - Normal position. Enginestarts must be possible.• NEUTRAL position - Engine running and brakesapplied, apply upward force on the shift arm. Trans-mission shall not be able to shift from neutral toreverse.FLUID AND FILTERDIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - EFFECTS OFINCORRECT FLUID LEVELA low fluid level allows the pump to take in airalong with the fluid. Air in the fluid will cause fluidpressures to be low and develop slower than normal.If the transmission is overfilled, the gears churn thefluid into foam. This aerates the fluid and causingthe same conditions occurring with a low level. Ineither case, air bubbles cause fluid overheating, oxi-dation, and varnish buildup which interferes withvalve and clutch operation. Foaming also causes fluidexpansion which can result in fluid overflow from thetransmission vent or fill tube. Fluid overflow can eas-ily be mistaken for a leak if inspection is not careful.DIAGNOSIS AND TESTING - CAUSES OFBURNT FLUIDBurnt, discolored fluid is a result of overheatingwhich has three primary causes.(1) Internal clutch slippage, usually caused by lowline pressure, inadequate clutch apply pressure, orclutch seal failure.(2) A result of restricted fluid flow through themain and/or auxiliary cooler. This condition is usu-ally the result of a faulty or improperly installeddrainback valve, a damaged oil cooler, or severerestrictions in the coolers and lines caused by debrisor kinked lines.(3) Heavy duty operation with a vehicle not prop-erly equipped for this type of operation. Trailer tow-ing or similar high load operation will overheat thetransmission fluid if the vehicle is improperlyequipped. Such vehicles should have an auxiliarytransmission fluid cooler, a heavy duty cooling sys-tem, and the engine/axle ratio combination needed tohandle heavy loads.DIAGNOSIS AND TESTING - FLUIDCONTAMINATIONTransmission fluid contamination is generally aresult of:• adding incorrect fluidDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 405BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM (Continued)
  57. 57. • failure to clean dipstick and fill tube whenchecking level• engine coolant entering the fluid• internal failure that generates debris• overheat that generates sludge (fluid break-down)• failure to replace contaminated converter afterrepairThe use of non-recommended fluids can result intransmission failure. The usual results are erraticshifts, slippage, abnormal wear and eventual failuredue to fluid breakdown and sludge formation. Avoidthis condition by using recommended fluids only.The dipstick cap and fill tube should be wipedclean before checking fluid level. Dirt, grease andother foreign material on the cap and tube could fallinto the tube if not removed beforehand. Take thetime to wipe the cap and tube clean before withdraw-ing the dipstick.Engine coolant in the transmission fluid is gener-ally caused by a cooler malfunction. The only remedyis to replace the radiator as the cooler in the radiatoris not a serviceable part. If coolant has circulatedthrough the transmission, an overhaul is necessary.The torque converter should also be replaced when-ever a failure generates sludge and debris. This isnecessary because normal converter flushing proce-dures will not remove all contaminants.STANDARD PROCEDURESTANDARD PROCEDURE - FLUID LEVELCHECKLow fluid level can cause a variety of conditionsbecause it allows the pump to take in air along withthe fluid. As in any hydraulic system, air bubblesmake the fluid spongy, therefore, pressures will below and build up slowly.Improper filling can also raise the fluid level toohigh. When the transmssion has too much fluid, thegeartrain churns up foam and cause the same condi-tions which occur with a low fluid level.In either case, air bubbles can cause overheatingand/or fluid oxidation, and varnishing. This caninterfere with normal valve, clutch, and accumulatoroperation. Foaming can also result in fluid escapingfrom the transmission vent where it may be mis-taken for a leak.After the fluid has been checked, seat the dipstickfully to seal out water and dirt.The transmission has a dipstick to check oil level.It is located on the right side of the engine. Be sureto wipe all dirt from dipstick handle before removing.The torque converter fills in both the P (PARK)and N (NEUTRAL) positions. Place the selector leverin P (PARK) to be sure that the fluid level check isaccurate. The engine should be running at idlespeed for at least one minute, with the vehicleon level ground. At normal operating temperature(approximately 82 C. or 180 F.), the fluid level is cor-rect if it is in the HOT region (cross-hatched area) onthe oil level indicator. The fluid level will be approx-imately at the upper COLD hole of the dipstick at70° F fluid temperature.NOTE: Engine and Transmission should be at nor-mal operating temperature before performing thisprocedure.(1) Start engine and apply parking brake.(2) Shift the transmission into DRIVE for approxi-mately 2 seconds.(3) Shift the transmission into REVERSE forapproximately 2 seconds.(4) Shift the transmission into PARK.(5) Hook up DRB௡ scan tool and select transmis-sion.(6) Select sensors.(7) Read the transmission temperature value.(8) Compare the fluid temperature value with thechart. (Fig. 71)(9) Adjust transmission fluid level shown on thedipstick according to the Transmission Fluid Temper-ature Chart.NOTE: After adding any fluid to the transmission,wait a minimum of 2 minutes for the oil to fullydrain from the fill tube into the transmission beforerechecking the fluid level.(10) Check transmission for leaks.STANDARD PROCEDURE - FLUID AND FILTERREPLACEMENTFor proper service intervals (Refer to LUBRICA-TION & MAINTENANCE/MAINTENANCE SCHED-ULES - DESCRIPTION).REMOVAL(1) Hoist and support vehicle on safety stands.(2) Place a large diameter shallow drain panbeneath the transmission pan.(3) Remove bolts holding front and sides of pan totransmission.(4) Loosen bolts holding rear of pan to transmis-sion.(5) Slowly separate front of pan away from trans-mission allowing the fluid to drain into drain pan.(6) Hold up pan and remove remaining bolts hold-ing pan to transmission.(7) While holding pan level, lower pan away fromtransmission.21 - 406 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRFLUID AND FILTER (Continued)
  58. 58. (8) Pour remaining fluid in pan into drain pan.(9) Remove the screw holding the primary oil filter(1) to valve body. (Fig. 72)(10) Separate filter from valve body and oil pumpand pour fluid in filter into drain pan.(11) Remove and discard the oil filter seal from thebottom of the oil pump.(12) If replacing the cooler return filter (2), use OilFilter Wrench 8321 to remove the filter from thetransmission.(13) Dispose of used trans fluid and filter(s) prop-erly.INSPECTIONInspect bottom of pan and magnet for excessiveamounts of metal. A light coating of clutch materialon the bottom of the pan does not indicate a problemunless accompanied by a slipping condition or shiftlag. If fluid and pan are contaminated with excessiveamounts of debris, refer to the diagnosis section ofthis group.CLEANING(1) Using a suitable solvent, clean pan and mag-net.(2) Using a suitable gasket scraper, clean originalsealing material from surface of transmission caseand the transmission pan.Fig. 71 Transmission Fluid Temperature ChartFig. 72 Transmission Filters - 4X4 Shown1 - PRIMARY OIL FILTER2 - COOLER RETURN FILTER3 - COOLER RETURN FILTER BYPASS VALVE4 - VALVE BODYDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 407FLUID AND FILTER (Continued)
  59. 59. INSTALLATIONCAUTION: The primary oil filter seal MUST be fullyinstalled flush against the oil pump body. DO NOTinstall the seal onto the filter neck and attempt toinstall the filter and seal as an assembly. Damage tothe transmission will result.(1) Install a new primary oil filter seal in the oilpump inlet bore. Seat the seal in the bore with thebutt end of a hammer, or other suitable tool.(2) Place replacement filter in position on valvebody and into the oil pump.(3) Install screw to hold the primary oil filter (1)(Fig. 72) to valve body. Tighten screw to 4.5 N·m (40in. lbs.) torque.(4) Install new cooler return filter (2) onto thetransmission, if necessary. Torque the filter to 14.12N·m (125 in.lbs.).(5) Place bead of Mopar௡ RTV sealant onto thetransmission case sealing surface.(6) Place pan in position on transmission.(7) Install bolts to hold pan to transmission.Tighten bolts to 11.8 N·m (105 in. lbs.) torque.(8) Lower vehicle and fill transmission withMopar௡ ATF +4.STANDARD PROCEDURE - TRANSMISSIONFILLTo avoid overfilling transmission after a fluidchange or overhaul, perform the following procedure:(1) Remove dipstick and insert clean funnel intransmission fill tube.(2) Add following initial quantity of Mopar௡ ATF+4 to transmission:(a) If only fluid and filter were changed, add 10pints (5 quarts) of ATF +4 to transmission.(b) If transmission was completely overhauledand the torque converter was replaced or drained,add 24 pints (12 quarts) of ATF +4 to transmis-sion.(3) Check the transmission fluid (Refer to 21 -TRANSMISSION/AUTOMATIC - RFE/FLUID -STANDARD PROCEDURE) and adjust as required.GEARSHIFT CABLEDIAGNOSIS AND TESTING - GEARSHIFTCABLE(1) Engine starts must be possible with shift leverin PARK or NEUTRAL positions only. Engine startsmust not be possible in any other gear position.(2) With the shift lever in the:(a) PARK position - Apply upward force on theshift arm and remove pressure. Engine starts mustbe possible.(b) PARK position - Apply downward force onthe shift arm and remove pressure. Engine startsmust be possible.(c) NEUTRAL position - Normal position. Enginestarts must be possible.(d) NEUTRAL position - Engine running andbrakes applied, apply upward force on the shiftarm. Transmission shall not be able to shift fromneutral to reverse.REMOVAL(1) Shift transmission into PARK.(2) Raise vehicle.(3) Disengage cable (1) eyelet at transmissionmanual shift lever (3) and pull cable adjuster out ofmounting bracket. (Fig. 73)(4) Lower the vehicle.Fig. 73 Gearshift Cable at Transmission - RFE1 - GEARSHIFT CABLE2 - RFE TRANSMISSION3 - MANUAL LEVER21 - 408 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRFLUID AND FILTER (Continued)
  60. 60. (5) Remove the dash panel insulation pad as nec-essary to access the gearshift cable grommet (2). (Fig.74)(6) Remove grommet (2) from the dash panel.(7) Remove any steering column (1) trim necessaryto access the gearshift cable (2) and BTSI mecha-nism.(8) Disconnect the BTSI wiring connector (5).(9) Disconnect cable at lower column bracket andshift lever pin and pull the cable through the dashpanel opening into the vehicle. (Fig. 75)(10) Remove gearshift cable (2) from vehicle.INSTALLATION(1) Route the transmission end of the gearshiftcable (1) through the opening in the dash panel. (Fig.76)(2) Seat the cable grommet (2) into the dash panelopening.(3) Snap the cable into the steering column (1)bracket so the retaining ears (Fig. 77) are engagedand snap the cable eyelet onto the shift lever ballstud.(4) Raise the vehicle.(5) Place the transmission manual shift lever inthe “PARK” detent (rearmost) position and rotateprop shaft to ensure transmission is in PARK.Fig. 74 Gearshift Cable at the Dash Panel1 - GEARSHIFT CABLE2 - GROMMETFig. 75 Gearshift Cable at Steering Column1 - STEERING COLUMN2 - GEARSHIFT CABLE3 - GEARSHIFT CABLE LOCK TAB4 - BTSI SOLENOID LOCK TAB5 - BTSI CONNECTORFig. 76 Gearshift Cable at the Dash Panel1 - GEARSHIFT CABLE2 - GROMMETFig. 77 Gearshift Cable at Steering Column1 - STEERING COLUMN2 - GEARSHIFT CABLE3 - GEARSHIFT CABLE LOCK TAB4 - BTSI SOLENOID LOCK TAB5 - BTSI CONNECTORDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 409GEARSHIFT CABLE (Continued)
  61. 61. (6) Route the gearshift cable through the transmis-sion mounting bracket and secure the cable by snap-ping the cable retaining ears into the transmissionbracket and snapping the cable eyelet on the manualshift lever ball stud.(7) Lower vehicle.(8) Lock the shift cable adjustment by pressing thecable adjuster lock tab (3) downward until it snapsinto place.(9) Check for proper operation of the transmissionrange sensor.(10) Adjust the gearshift cable (Refer to 21 -TRANSMISSION/AUTOMATIC/GEAR SHIFTCABLE - ADJUSTMENTS) and BTSI mechanism(Refer to 21 - TRANSMISSION/AUTOMATIC/BRAKE TRANSMISSION SHIFT INTERLOCK SYS-TEM - ADJUSTMENTS) as necessary.ADJUSTMENTS - GEARSHIFT CABLECheck adjustment by starting the engine in PARKand NEUTRAL. Adjustment is CORRECT if theengine starts only in these positions. Adjustment isINCORRECT if the engine starts in one but not bothpositions. If the engine starts in any position otherthan PARK or NEUTRAL, or if the engine will notstart at all, the transmission range sensor may befaulty.Gearshift Adjustment Procedure(1) Shift transmission into PARK.(2) Release cable adjuster lock tab (3) (underneaththe steering column) (Fig. 78) to unlock cable.(3) Raise vehicle.(4) Disengage the cable eyelet from the transmis-sion manual shift lever.(5) Verify transmission shift lever is in PARKdetent by moving lever fully rearward. Last rearwarddetent is PARK position.(6) Verify positive engagement of transmissionpark lock by attempting to rotate propeller shaft.Shaft will not rotate when park lock is engaged.(7) Snap the cable eyelet onto the transmissionmanual shift lever.(8) Lower vehicle.(9) Lock shift cable by pressing cable adjuster locktab (3) downward until it snaps into place.(10) Check engine starting. Engine should startonly in PARK and NEUTRAL.Fig. 78 Gearshift Cable at Steering Column1 - STEERING COLUMN2 - GEARSHIFT CABLE3 - GEARSHIFT CABLE LOCK TAB4 - BTSI SOLENOID LOCK TAB5 - BTSI CONNECTOR21 - 410 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRGEARSHIFT CABLE (Continued)
  62. 62. HOLDING CLUTCHESDESCRIPTIONThree hydraulically applied multi-disc clutches areused to hold some planetary geartrain componentsstationary while the input clutches drive others. The2C, 4C, and Low/Reverse clutches are consideredholding clutches. The 2C and 4C clutches are locatedin the 4C retainer/bulkhead (13). (Fig. 79)The Low/Reverse clutch is located at the rear ofthe transmission case. (Fig. 80)OPERATION2C CLUTCHThe 2C clutch is hydraulically applied in secondand fifth gear by pressurized fluid against the 2Cpiston. When the 2C clutch is applied, the reversesun gear assembly is held or grounded to the trans-mission case by holding the reaction planetary car-rier.4C CLUTCHThe 4C clutch is hydraulically applied in secondprime and fourth gear by pressurized fluid againstthe 4C clutch piston. When the 4C clutch is applied,the reaction annulus gear is held or grounded to thetransmission case.Fig. 79 2C and 4C Clutches1 - SEAL 8 - REACTION PLATE2 - 2C PISTON 9 - SNAP-RING3 - PLATE 10 - RETURN SPRING4 - DISC 11 - SEAL5 - 2C BELLEVILLE SPRING 12 - 4C PISTON6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD7 - SNAP-RING (SELECT)DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 411
  63. 63. LOW/REVERSE CLUTCHThe Low/Reverse clutch is hydraulically applied inpark, reverse, neutral, and first gear, only at lowspeeds, by pressurized fluid against the Low/Reverseclutch piston. When the Low/Reverse clutch isapplied, the input annulus assembly is held orgrounded to the transmission case.Fig. 80 Low/Reverse Clutch1 - SNAP-RING (SELECT) 8 - SEAL2 - REACTION PLATE 9 - BELLEVILLE SPRING3 - DISC 10 - RETAINER4 - PLATE 11 - SNAP-RING5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH6 - SEAL 13 - SNAP-RING7 - PISTON21 - 412 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRHOLDING CLUTCHES (Continued)
  64. 64. INPUT CLUTCH ASSEMBLYDESCRIPTIONThree hydraulically applied input clutches are usedto drive planetary components. The underdrive, over-drive, and reverse clutches are considered inputclutches and are contained within the input clutchassembly. (Fig. 81) (Fig. 82)The input clutch assembly also contains:• Input shaft• Input hub• Clutch retainer• Underdrive piston• Overdrive/reverse piston• Overdrive hub• Underdrive hubOPERATIONThe three input clutches are responsible for drivingdifferent components of the planetary geartrain.UNDERDRIVE CLUTCHThe underdrive clutch is hydraulically applied infirst, second, second prime, and third (direct) gearsby pressurized fluid against the underdrive piston.When the underdrive clutch is applied, the under-drive hub drives the input sun gear.Fig. 81 Input Clutch Assembly - Part 11 - INPUT CLUTCH HUB 11 - UD CLUTCH2 - O-RING SEALS 12 - PLATE3 - SEAL 13 - CLUTCH RETAINER4 - SNAP-RING 14 - SEAL5 - SNAP-RING 15 - OD/REV PISTON6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING7 - SNAP-RING 17 - SNAP-RING8 - UD PISTON 18 - SEAL RINGS9 - SPRING 19 - INPUT SHAFT10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RINGDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 413
  65. 65. OVERDRIVE CLUTCHThe overdrive clutch is hydraulically applied inthird (direct), fourth, and fifth gears by pressurizedfluid against the overdrive/reverse piston. When theoverdrive clutch is applied, the overdrive hub drivesthe reverse carrier/input annulus assembly.REVERSE CLUTCHThe reverse clutch is hydraulically applied inreverse gear by pressurized fluid against the over-drive/reverse piston. When the reverse clutch isapplied, the reaction annulus gear is driven.DISASSEMBLY(1) Remove the reverse reaction plate selectivesnap-ring (10) from the input clutch retainer (13).(Fig. 83)(2) Remove the reverse reaction plate (9) from theinput clutch retainer (13).(3) Remove the reverse hub (7) and reverse clutchpack (8) from the input clutch retainer (13).(4) Remove the number 4 thrust bearing (5) fromthe overdrive hub (2).(5) Remove the overdrive hub (2) from the inputclutch retainer (13). (Fig. 83)Fig. 82 Input Clutch Assembly - Part 21 - THRUST BEARING NUMBER 3 10 - SNAP-RING (SELECT)2 - OD HUB/SHAFT 11 - PLATE3 - SNAP-RING (WAVE) 12 - DISC4 - REV/OD REACTION PLATE 13 - OD CLUTCH5 - THRUST BEARING NUMBER 4 14 - SNAP-RING (TAPERED)6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)8 - REVERSE CLUTCH 17 - UD HUB/SHAFT9 - REVERSE REACTION PLATE 18 - THRUST BEARING NUMBER 221 - 414 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRINPUT CLUTCH ASSEMBLY (Continued)
  66. 66. (6) Remove the number 3 thrust bearing (1) fromthe underdrive hub (17).(7) Remove the OD/reverse reaction plate snap-ring (6) from the input clutch retainer (13).(8) Remove the underdrive hub (17), overdriveclutch (13), and overdrive reaction plate (15) from theinput clutch retainer (13). (Fig. 83)NOTE: The overdrive friction discs and steel discsare thicker than the matching components in theunderdrive and reverse clutches.Fig. 83 Input Clutch Assembly - Part 21 - THRUST BEARING NUMBER 3 10 - SNAP-RING (SELECT)2 - OD HUB/SHAFT 11 - PLATE3 - SNAP-RING (WAVE) 12 - DISC4 - REV/OD REACTION PLATE 13 - OD CLUTCH5 - THRUST BEARING NUMBER 4 14 - SNAP-RING (TAPERED)6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)8 - REVERSE CLUTCH 17 - UD HUB/SHAFT9 - REVERSE REACTION PLATE 18 - THRUST BEARING NUMBER 2DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 415INPUT CLUTCH ASSEMBLY (Continued)
  67. 67. (9) Remove the number 2 thrust bearing (18) fromthe input clutch hub (1).(10) Remove the overdrive clutch wave snap-ring(3) from the input clutch retainer (13).(11) Remove the UD/OD reaction plate taperedsnap-ring (14) from the input clutch retainer (13).(12) Remove the UD/OD reaction plate (15) fromthe input clutch retainer (13).(13) Remove the UD/OD reaction plate flat snap-ring (16) from the input clutch retainer (13). (Fig. 83)(14) Remove the underdrive clutch pack (11) fromthe input clutch retainer (13). (Fig. 84)(15) Using Spring Compressor 8251 (2) , compressthe UD/OD balance piston (3) and remove the snap-ring from the input clutch hub (1). (Fig. 85)(16) Remove the UD/OD balance piston (6) andpiston return spring (9) from the input clutchretainer (13). (Fig. 84)(17) Remove the underdrive piston (8) from theinput clutch retainer (13). (Fig. 84)NOTE: Both the UD/OD balance piston and theunderdrive piston have seals molded onto them. Ifthe seal is damaged, do not attempt to install a newseal onto the piston. The piston/seal must bereplaced as an assembly.Fig. 84 Input Clutch Assembly - Part 11 - INPUT CLUTCH HUB 11 - UD CLUTCH2 - O-RING SEALS 12 - PLATE3 - SEAL 13 - CLUTCH RETAINER4 - SNAP-RING 14 - SEAL5 - SNAP-RING 15 - OD/REV PISTON6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING7 - SNAP-RING 17 - SNAP-RING8 - UD PISTON 18 - SEAL RINGS9 - SPRING 19 - INPUT SHAFT10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING21 - 416 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRINPUT CLUTCH ASSEMBLY (Continued)
  68. 68. (18) Remove the input clutch retainer taperedsnap-ring (5).(19) Separate input clutch retainer (13) from inputclutch hub (1).(20) Separate OD/reverse piston (15) from inputclutch hub retainer (13). (Fig. 84)(21) Remove all seals and o-rings from the inputshaft and input hub. The o-rings on the input hubare color coded. Be sure to make note of which o-ringbelongs in which location.ASSEMBLYNOTE: Install all new seals and o-rings onto theinput shaft and input hub. The o-rings on the inputhub are color coded. Be sure to install the correcto-ring in the correct location.(1) Check the transmission lubrication check valve(20) located in the input shaft using shop air. Thevalve should only allow air flow in one direction. Ifthe valve allows no air flow, or air flow in both direc-tions, the valve will need to be replaced.(2) Lubricate all seals with Mopar௡ ATF +4, Auto-matic Transmission Fluid, prior to installation.(3) Assemble the OD/reverse piston (15) onto theinput clutch hub (1). (Fig. 86)(4) Assemble the input clutch retainer (13) ontothe input clutch hub (1).(5) Install the input clutch retainer tapered snap-ring (5) with tapered side up onto the input clutchhub (1).Fig. 85 Compressing UD/OD Balance Piston UsingTool 82511 - PRESS2 - TOOL 82513 - BALANCE PISTONDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 417INPUT CLUTCH ASSEMBLY (Continued)
  69. 69. Fig. 86 Input Clutch Assembly - Part 11 - INPUT CLUTCH HUB 11 - UD CLUTCH2 - O-RING SEALS 12 - PLATE3 - SEAL 13 - CLUTCH RETAINER4 - SNAP-RING 14 - SEAL5 - SNAP-RING 15 - OD/REV PISTON6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING7 - SNAP-RING 17 - SNAP-RING8 - UD PISTON 18 - SEAL RINGS9 - SPRING 19 - INPUT SHAFT10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING21 - 418 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRINPUT CLUTCH ASSEMBLY (Continued)
  70. 70. (6) Install Piston Guides 8504 (1) into the inputclutch retainer (13) (Fig. 87) and onto the inputclutch hub (1) to guide the inner and outer under-drive piston (8) seals into position.(7) Install the underdrive piston (8) into the inputclutch retainer (13) and over the input clutch hub (1).(Fig. 86)(8) Install the UD/OD balance piston return springpack (9) into the input clutch retainer (13).(9) Install Piston Guide 8252 (1) into the inputclutch retainer (13) (Fig. 88) to guide the UD/OD bal-ance piston (6) seal into position inside the under-drive piston (8).(10) Install the UD/OD balance piston (3) into theinput clutch retainer and the underdrive piston.(11) Using Spring Compressor 8251 (2), compressthe UD/OD return spring pack and secure the pistonin place with the snap-ring. (Fig. 89)(12) Install the underdrive clutch pack (11) intothe input clutch retainer. (Fig. 86)(13) Install the UD/OD reaction plate lower flatsnap-ring (16) (Fig. 90). The correct snap-ring can beidentified by the two tabbed ears.(14) Install the UD/OD reaction plate (15) into theinput clutch retainer. The reaction plate is to beinstalled with the big step down.(15) Install the UD/OD reaction plate uppertapered snap-ring (14) with tapered side up.(16) Install the input clutch assembly into InputClutch Pressure Fixture 8260 (2). (Fig. 91)(17) Mount a dial indicator to the assembly, pushdown on the clutch discs and zero the indicatoragainst the underdrive clutch discs (Fig. 92). Apply20 psi of air pressure to the underdrive clutch andrecord the dial indicator reading. Measure and recordUD clutch pack measurement in four (4) places, 90°apart. Take average of four measurements and com-pare with UD clutch pack clearance specification.The correct clutch clearance is 0.84-1.54 mm (0.033-0.061 in.). The reaction plate is not selective. If theclutch clearance is not within specification, replacethe reaction plate along with all the friction and steeldiscs.(18) Install the overdrive clutch pack (13) into theinput clutch retainer (Fig. 90). The overdrive steelFig. 87 Install Underdrive Piston Using Tool 85041 - TOOL 8504Fig. 88 Install Balance Piston Using Tool 82521 - TOOL 8252Fig. 89 Compressing UD/OD Balance Piston UsingTool 82511 - PRESS2 - TOOL 82513 - BALANCE PISTONDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 419INPUT CLUTCH ASSEMBLY (Continued)
  71. 71. separator plates can be identified by the lack of thehalf-moon cuts in the locating tabs.(19) Install the overdrive clutch wavy snap-ring (3)with the two tabbed ears into the input clutchretainer.(20) Install the OD/reverse reaction plate (4) intothe input clutch retainer. The reaction plate is non-directional. (Fig. 90)(21) Install the OD/reverse reaction plate flatsnap-ring (6) into the input clutch retainer.(22) Mount a dial indicator to the assembly andzero the indicator against the OD/reverse reactionplate (2) (Fig. 93). Apply 20 psi of air pressure to theoverdrive clutch and record the dial indicator read-ing. Measure and record OD clutch pack measure-ment in four (4) places, 90° apart. Take average offour measurements and compare with OD clutchpack clearance specification.Verify that the clutchclearance is 1.103-1.856 mm (0.043-0.073 in.). Thereaction plate is not selective. If the clutch clearanceis not within specification, replace the reaction platealong with all the friction and steel discs.(23) Install the reverse clutch pack (8) into theinput clutch retainer. (Fig. 90)Fig. 90 Input Clutch Assembly - Part 21 - THRUST BEARING NUMBER 3 10 - SNAP-RING (SELECT)2 - OD HUB/SHAFT 11 - PLATE3 - SNAP-RING (WAVE) 12 - DISC4 - REV/OD REACTION PLATE 13 - OD CLUTCH5 - THRUST BEARING NUMBER 4 14 - SNAP-RING (TAPERED)6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)8 - REVERSE CLUTCH 17 - UD HUB/SHAFT9 - REVERSE REACTION PLATE 18 - THRUST BEARING NUMBER 221 - 420 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRINPUT CLUTCH ASSEMBLY (Continued)
  72. 72. (24) Install the reverse reaction plate(9) into theinput clutch retainer.(25) Install the reverse reaction plate selectivesnap-ring (10) into the input clutch retainer.(26) Mount a dial indicator to the assembly, pushdown on the clutch discs, pull up on the reactionplate to ensure the plate is properly seated and zerothe indicator against the reverse clutch discs (2) (Fig.94). Apply 20 psi of air pressure to the reverse clutchand record the dial indicator reading. Measure andrecord Reverse clutch pack measurement in four (4)places, 90° apart. Take average of four measurementsand compare with Reverse clutch pack clearancespecification. The correct clutch clearance is 0.58-1.47mm (0.023-0.058 in.). Adjust as necessary. Install thechosen snap-ring and re-measure to verify selection.(27) Remove the reverse clutch pack (8) from theinput clutch retainer.Fig. 91 Input Clutch Assembly Mounted on Tool82601 - INPUT CLUTCH ASSEMBLY2 - TOOL 8260Fig. 92 Measuring UD Clutch Clearance1 - TOOL C-33392 - UNDERDRIVE CLUTCH PACKFig. 93 Measuring OD Clutch Clearance1 - TOOL C-33392 - OD/REV REACTION PLATEFig. 94 Measuring Reverse Clutch Clearance1 - TOOL C-33392 - REVERSE CLUTCH PACKDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 421INPUT CLUTCH ASSEMBLY (Continued)
  73. 73. (28) Install the number 2 thrust bearing (18) ontothe underdrive hub (17) with outer race against thehub with petroleum jelly.(29) Install the underdrive hub (17) into the inputclutch retainer.(30) Install the number 3 thrust bearing (1) intothe overdrive hub (2) with the outer race against thehub with petroleum jelly.(31) Install the overdrive hub (2) into the inputclutch retainer.(32) Install the number 4 thrust bearing (5) intothe reverse hub with outer race against the hub withpetroleum jelly.(33) Install the reverse hub (7) into the inputclutch retainer.(34) Install the complete reverse clutch pack (8).(35) Install the reverse reaction plate (9) and snap-ring (10).(36) Push up on reaction plate to allow reverseclutch to move freely.INPUT SPEED SENSORDESCRIPTIONThe Input and Output Speed Sensors are two-wiremagnetic pickup devices that generate AC signals asrotation occurs. They are mounted in the left side ofthe transmission case and are considered primaryinputs to the Transmission Control Module (TCM).OPERATIONThe Input Speed Sensor provides information onhow fast the input shaft is rotating. As the teeth ofthe input clutch hub pass by the sensor coil, an ACvoltage is generated and sent to the TCM. The TCMinterprets this information as input shaft rpm.The Output Speed Sensor generates an AC signalin a similar fashion, though its coil is excited by rota-tion of the rear planetary carrier lugs. The TCMinterprets this information as output shaft rpm.The TCM compares the input and output speedsignals to determine the following:• Transmission gear ratio• Speed ratio error detection• CVI calculationThe TCM also compares the input speed signal andthe engine speed signal to determine the following:• Torque converter clutch slippage• Torque converter element speed ratioREMOVAL(1) Raise vehicle.(2) Place a suitable fluid catch pan under thetransmission.(3) Remove the wiring connector from the inputspeed sensor (3). (Fig. 95)(4) Remove the bolt holding the input speed sensorto the transmission case.(5) Remove the input speed sensor (3) from thetransmission case.INSTALLATION(1) Install the input speed sensor (3) (Fig. 96) intothe transmission case.Fig. 95 Input Speed Sensor1 - OUTPUT SPEED SENSOR2 - LINE PRESSURE SENSOR3 - INPUT SPEED SENSORFig. 96 Input Speed Sensor1 - OUTPUT SPEED SENSOR2 - LINE PRESSURE SENSOR3 - INPUT SPEED SENSOR21 - 422 AUTOMATIC TRANSMISSION - 45RFE/545RFE DRINPUT CLUTCH ASSEMBLY (Continued)
  74. 74. (2) Install the bolt to hold the input speed sensor(3) into the transmission case. Tighten the bolt to11.9 N·m (105 in.lbs.).(3) Install the wiring connector onto the inputspeed sensor.(4) Verify the transmission fluid level. Add fluid asnecessary.(5) Lower vehicle.LINE PRESSURE (LP) SENSORDESCRIPTIONThe TCM utilizes a closed-loop system to controltransmission line pressure. The system contains avariable force style solenoid, the Pressure ControlSolenoid, mounted on the side of the solenoid andpressure switch assembly. The solenoid is duty cyclecontrolled by the TCM to vent the unnecessary linepressure supplied by the oil pump back to the sump.The system also contains a variable pressure stylesensor, the Line Pressure Sensor, which is a directinput to the TCM. The line pressure solenoid moni-tors the transmission line pressure and completes thefeedback loop to the TCM. The TCM uses this infor-mation to adjust its control of the pressure controlsolenoid to achieve the desired line pressure.OPERATIONThe TCM calculates the desired line pressurebased upon inputs from the transmission and engine.The TCM calculates the torque input to the trans-mission and uses that information as the primaryinput to the calculation. The line pressure is set to apredetermined value during shifts and when thetransmission is in the PARK and NEUTRAL posi-tions. This is done to ensure consistent shift quality.During all other operation, the actual line pressure iscompared to the desired line pressure and adjust-ments are made to the pressure control solenoid dutycycle.REMOVAL(1) Raise vehicle.(2) Place a suitable fluid catch pan under thetransmission.(3) Remove the wiring connector from the linepressure sensor (2). (Fig. 97)(4) Remove the bolt holding the line pressure sen-sor (2) to the transmission case.(5) Remove the line pressure sensor (2) from thetransmission case.INSTALLATION(1) Install the line pressure sensor (2) (Fig. 98)into the transmission case.(2) Install the bolt to hold the line pressure sensor(2) into the transmission case. Tighten the bolt to11.9 N·m (105 in.lbs.).(3) Install the wiring connector onto the line pres-sure sensor (2).(4) Verify the transmission fluid level. Add fluid asnecessary.(5) Lower vehicle.Fig. 97 Line Pressure Sensor1 - OUTPUT SPEED SENSOR2 - LINE PRESSURE SENSOR3 - INPUT SPEED SENSORFig. 98 Line Pressure Sensor1 - OUTPUT SPEED SENSOR2 - LINE PRESSURE SENSOR3 - INPUT SPEED SENSORDR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 423INPUT SPEED SENSOR (Continued)
  75. 75. LOW/REVERSE CLUTCHDISASSEMBLY(1) Remove the inner overrunning clutch snap-ring(13) from the low/reverse clutch retainer (5). (Fig. 99)(2) Remove the outer low/reverse reaction plateflat snap-ring (1. (Fig. 99)(3) Remove the low/reverse clutch (3, 4) and theoverrunning clutch (12) from the low/reverse clutchretainer (5) as an assembly. (Fig. 99)(4) Separate the low/reverse clutch (3, 4) from theoverrunning clutch (12).Fig. 99 Low/Reverse Clutch Assembly1 - SNAP-RING (SELECT) 8 - SEAL2 - REACTION PLATE 9 - BELLEVILLE SPRING3 - DISC 10 - RETAINER4 - PLATE 11 - SNAP-RING5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH6 - SEAL 13 - SNAP-RING7 - PISTON21 - 424 AUTOMATIC TRANSMISSION - 45RFE/545RFE DR

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