1998 DODGE RAM 1500 one

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
CAUTION: Before attempting any repair on a RFE
automatic transmission, check for Diagnostic Trou-
ble Codes with the DRBTscan tool.
Transmission malfunctions may be caused by these
general conditions:
²Poor engine performance
²Improper adjustments
²Hydraulic malfunctions
²Mechanical malfunctions
²Electronic malfunctions
Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or if more diagnosis is necessary. If the
problem persists after the preliminary tests and cor-
rections are completed, hydraulic pressure checks
should be performed.
DIAGNOSIS AND TESTING - PRELIMINARY
Two basic procedures are required. One procedure
for vehicles that are drivable and an alternate proce-
dure for disabled vehicles (will not back up or move
forward).
VEHICLE IS DRIVABLE
(1) Check for transmission fault codes using DRBt
scan tool.
(2) Check fluid level and condition.
(3) Adjust gearshift cable if complaint was based
on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
(5) Perform hydraulic pressure test if shift 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 gearshift
cable.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmis-
sion is noisy, stop engine. Remove oil pan, and
check 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 to
determine if problem is hydraulic or mechanical.
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testing, be sure the fluid level and con-
trol cable adjustments have been checked and
adjusted 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. Check
for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means
clutch, 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 charts
provide a basis for analyzing road test results.
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

is applied. The clutch application can also be felt by
touching the appropriate element while applying air
pressure. As the air pressure is released, the clutch
should also release.
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK
When 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 may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill or fill after repair.
Converter housing leaks have several potential
sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair. Torque converter seal leaks tend to move
along the drive hub and onto the rear of the con-
verter. Pump cover seal tend to run down the cover
and the inside surface of the bellhousing.
Some leaks, or suspected leaks, may be particu-
larly difficult to locate. If necessary, a Mopart
approved dye may be used to locate a leak.
TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
(1) Leaks at the weld joint around the outside
diameter weld (Fig. 7).
(2) Leaks at the converter hub weld (Fig. 7).
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
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 CASE
SKID PLATE - REMOVAL)
(4) Mark propeller shaft and axle companion
flanges 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 the
rear of the transmission.
(9) Disconnect and lower or remove any necessary
exhaust components.
Fig. 7 Torque Converter Assembly
1 - TURBINE ASSEMBLY
2-STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - STRUCTURAL DUST COVER
3 - TRANSMISSION
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(10) Remove the starter motor.
(11) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(12) Disengage the output speed sensor connector
from the output speed sensor (Fig. 9).
(13) Disengage the input speed sensor connector
from the input speed sensor (Fig. 10).(14) Disengage the transmission solenoid/TRS
assembly connector from the transmission solenoid/
TRS assembly (Fig. 11).
(15) Disengage the line pressure sensor connector
from the line pressure sensor (Fig. 12).
Fig. 9 Disconnect Output Speed Sensor
1 - TRANSMISSION
2 - OUTPUT SPEED SENSOR
Fig. 10 Disconnect Input Speed Sensor
1 - TRANSMISSION
2 - INPUT SPEED SENSOR
Fig. 11 Disconnect Transmission Solenoid/TRS
Assembly
1 - TRANSMISSION
2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
Fig. 12 Disconnect Line Pressure Sensor
1 - TRANSMISSION
2 - LINE PRESSURE SENSOR
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(43) Remove the park pawl rod and e-clip (Fig. 31).
(44) Remove the park pawl rod guide snap-ring
(Fig. 31).
(45) Remove the park pawl rod guide (Fig. 31).
(46) Remove the park pawl pivot shaft, park pawl,
and spring (Fig. 31).
(47) Remove the manual selector shaft (Fig. 31).
(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
CLEANING
The 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 sharp
edges. Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or O-rings
during overhaul. Replace these parts as a matter of
course. Also do not reuse snap rings or E-clips that are
bent or distorted. Replace these parts as well.
Lubricate transmission parts with MopartATF +4,
Automatic Transmission Fluid, during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-Glyde to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the cooler filter bypass valve.
(3) Torque the bypass valve to specification. The
valve uses a tapered pipe thread and excessive
torque can damage the transmission case. Tighten
the cooler filter bypass valve to 4.5 N´m (40 in.lbs.).
(4) Install a new selector shaft seal using Seal
Installer 8253 (Fig. 32).
Fig. 31 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 32 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(5) Install the manual selector shaft and retaining
screw. Tighten the manual selector shaft retaining
screw to 28 N´m (250 in.lbs.).
(6) Install the park pawl, spring, and shaft (Fig.
33).
(7) Install the park rod and e-clip (Fig. 33).
(8) Install the park rod guide and snap-ring (Fig.
33).
(9) Install a new dipstick tube seal using Seal
Installer 8254 (Fig. 34).
NOTE: Before final assembly of transmission cen-
terline, the 2C/4C clutch components should be
installed into position and measured as follows:
(10) Install the 2C reaction plate into the trans-
mission case (Fig. 35).
(11) Install the 2C clutch pack into the transmis-
sion case (Fig. 35).
(12) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 35).
(13) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area.(14) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case. Make sure that
the open ends of the snap-ring are located in the case
opening toward the valve body area.
(15) Using a feeler gauge through the opening in
the rear of the transmission case, measure the 2C
clutch pack clearance between the 2C reaction plate
and the transmission case at four different points.
The average of these measurements is the 2C clutch
pack clearance. The correct clutch clearance is 0.455-
1.335 mm (0.018-0.053 in.). The reaction plate is not
selective. If the clutch pack clearance is not within
Fig. 33 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 34 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 35 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

specification, the reaction plate, all the friction discs,
and steels must be replaced.
(16) Remove the 4C retainer/bulkhead and all of
the 2C clutch components from the transmission
case.
(17) Install the low/reverse clutch assembly (Fig.
36). Make sure that the oil feed hole points toward
the valve body area and that the bleed orifice is
aligned with the notch in the rear of the transmis-
sion case.
(18) Install the snap-ring to hold the low/reverse
clutch retainer into the transmission case (Fig. 36).
The snap-ring is tapered and must be installed with
the tapered side forward. Once installed, verify that
the snap-ring is fully seated in the snap-ring groove.
(19) Air check the low/reverse clutch and verify
correct overrunning clutch operation.
(20) Install the number 12 bearing over the output
shaft and against the rear planetary gear set. The
flat side of the bearing goes toward the planetary
gearset and the raised tabs on the inner race should
face the rear of the transmission.
(21) Install the reverse/input planetary assembly
through the low/reverse clutch assembly (Fig. 37).
(22) Install the park sprag onto the output shaft
(Fig. 38).
Fig. 38 Install Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 36 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 37 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(31) Install the output shaft selective thrust plate
onto the reaction annulus with the oil grooves facing
the annulus gear and the tabs and notches aligned as
shown in (Fig. 42).
(32) Install the number 6 bearing against the out-
put shaft selective thrust plate with the flat side
against the thrust plate (Fig. 41) and the raised tabs
on the inner race facing the front of the transmis-
sion.
(33) Install the reaction annulus into the reaction
planetary gear set (Fig. 41).
(34) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the
reaction annulus during the installation of the 4C
retainer/bulkhead to ease installation.
(35) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case (Fig. 43) with
the taper toward the front of the case. Make sure
that the open ends of the snap-ring are located in the
case opening toward the valve body area.
(36) Air check the 2C and 4C clutch operation.
(37) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator
C-3339, measure and record the output shaft end-
play (Fig. 44). The correct output shaft end-play is
0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary.
Install the chosen output shaft selective thrust plate
and re-measure end-play to verify selection.
(38) Apply a bead of RTV silicone and install the
extension/adapter housing onto the transmission
case.(39) Install and torque the bolts to hold the exten-
sion/adapter housing onto the transmission case. The
correct torque is 54 N´m (40 ft.lbs.).
(40) Install the number 5 bearing and selective
thrust plate onto the 4C retainer/bulkhead (Fig. 45).
Be sure that the outer race of the bearing is against
the thrust plate.
(41) Install the input clutch assembly into the
transmission case (Fig. 45). Make sure that the input
clutch assembly is fully installed by performing a
Fig. 42 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 43 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 44 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

visual inspection through the input speed sensor
hole. If the tone wheel teeth on the input clutch
assembly are centered in the hole, the assembly is
fully installed.
(42) Install the number 1 bearing with the outer
race up in the pocket of the input clutch assembly
(Fig. 45).
(43) Install the oil pump into the transmission
case (Fig. 46).
(44) Install the bolts to hold the oil pump into the
transmission case. Tighten the oil pump bolts to 28
N´m (250 in.lbs.).
(45) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 47). The correct end-
play is 0.46-0.89 mm (0.018-0.035 in.). Adjust as nec-
essary. Install the chosen thrust plate on the number
5 bearing and re-measure end-play to verify selec-
tion.
NOTE: When measuring the input shaft end-play,
two(stops(will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first(stop(felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
Fig. 45 Install Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 46 Install Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 47 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
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AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)