1998 DODGE RAM 1500 ABS

thrust plate if worn, or severely scored. Replace the
driving shell if distorted, cracked, or damaged in any
way.
Replace all snap-rings during geartrain assembly.
Reusing snap-rings is not recommended.
ASSEMBLY
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly to lubricate intermediate shaft bushing surfaces,
thrust washers and thrust plates and to hold these
parts in place during assembly.
(2) Install front snap-ring on sun gear and install
gear in driving shell. Then install thrust plate over
sun gear and against rear side of driving shell (Fig.
201). Install rear snap-ring to secure sun gear and
thrust plate in driving shell. Note that the large ID
chamfer on the sun gear goes forward.
(3) Install rear annulus gear on intermediate shaft
(Fig. 202).
(4) Install thrust washer to rear planetary gear
(Fig. 203) using petroleum jelly. Be sure washer is
seated against corner witht teh tabs completely in
the locating holes.
(5) Install rear planetary gear in rear annulus
gear (Fig. 204). Be sure planetary carrier is seated
against annulus gear.
Fig. 202 Installing Rear Annulus Gear On
Intermediate Shaft
1 - REAR ANNULUS GEAR
2 - OUTPUT SHAFT
Fig. 203 Installing Rear Annulus Thrust Washer
1 - REAR ANNULUS GEAR
2 - THRUST WASHER
Fig. 204 Installing Rear Planetary Gear
1 - REAR ANNULUS GEAR
2 - REAR PLANETARY GEAR
Fig. 201 Sun Gear Installation
1 - DRIVING SHELL
2 - SUN GEAR
3 - THRUST PLATE
4 - SUN GEAR REAR RETAINING RING
21 - 244 AUTOMATIC TRANSMISSION - 48REDR
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(6) Install tabbed thrust washer on front face of
rear planetary gear (Fig. 205). Seat washer tabs in
matching slots in face of gear carrier. Use extra
petroleum jelly to hold washer in place if desired.
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
(8) Install sun gear and driving shell on interme-
diate shaft (Fig. 206). Seat shell against rear plane-
tary gear. Verify that thrust washer on planetary
gear was not displaced during installation.
(9) Install tabbed thrust washer in driving shell
(Fig. 207), be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
washer in place if desired.
(10) Install tabbed thrust washer on front plane-
tary gear (Fig. 208). Seat washer tabs in matchingslots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
(11) Install the torlon bushing onto the front plan-
etary carrier hub.
Fig. 205 Installing Rear Planetary Thrust Washer
1 - REAR PLANETARY GEAR
2 - TABBED THRUST WASHER
Fig. 206 Installing Sun Gear And Driving Shell
1 - OUTPUT SHAFT
2 - DRIVING SHELL
3 - REAR PLANETARY GEAR
4 - OUTPUT SHAFT
5 - SUN GEAR
Fig. 207 Installing Driving Shell Thrust Washer
1 - TAB SLOTS (3)
2 - DRIVING SHELL
3 - TABBED THRUST WASHER
Fig. 208 Installing Thrust Washer On Front
Planetary Gear
1 - TABBED THRUST WASHER
2 - FRONT PLANETARY GEAR
DRAUTOMATIC TRANSMISSION - 48RE 21 - 245
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(23) Remove left-side screw and remove 3-4 accu-
mulator housing from valve body (Fig. 291).
(24) Bend back tabs on boost valve tube brace (Fig.
292).(25) Remove boost valve connecting tube (Fig.
293). Disengage tube from upper housing port first.
Then rock opposite end of tube back and forth to
work it out of lower housing.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(26) Turn valve body over so lower housing is fac-
ing upward (Fig. 294). In this position, the two check
balls in upper housing will remain in place and not
fall out when lower housing and separator plate are
removed.
(27) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
294). Note position of boost valve tube brace for
assembly reference.
(28) Remove lower housing and overdrive separa-
tor plate from transfer plate (Fig. 294).
Fig. 293 Boost Valve Tube
1 - BOOST VALVE TUBE
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 294 Lower Housing
1 - LOWER HOUSING
2 - OVERDRIVE SEPARATOR PLATE
3 - TRANSFER PLATE AND UPPER HOUSING
Fig. 291 Accumulator Housing, Valve Springs, and
Plug
1 - 3-4 SHIFT VALVE SPRING
2 - CONVERTER CLUTCH VALVE SPRING AND PLUG
3 - 3-4 ACCUMULATOR HOUSING
Fig. 292 Boost Valve Tube Brace
1 - BOOST VALVE TUBE
2 - TUBE BRACE (DOUBLE TAB)
21 - 292 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

BOOST VALVE TUBE AND BRACE
(1) Position valve body assembly so lower housing
is facing upward (Fig. 318).
(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 318).
(4) Insert and seat each end of tube in housings.
(5) Slide tube brace under tube and into alignment
with valve body screw holes (Fig. 319).
(6) Install and finger tighten three screws that
secure tube brace to valve body housings (Fig. 319).
(7) Bend tube brace tabs up and against tube to
hold it in position (Fig. 320).
(8) Tighten all valve body housing screws to 4 N´m
(35 in. lbs.) torque after tube and brace are installed.
Tighten screws in diagonal pattern starting at center
and working outward.
Fig. 318 Boost Valve Tube
1 - BOOST VALVE TUBE
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 319 Boost Valve Tube And Brace
1 - BOOST VALVE TUBE
2 - TUBE BRACE
Fig. 320 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
21 - 306 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (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
21 - 328 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
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
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 331
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

separator plates can be identified by the lack of the
half-moon cuts in the locating tabs.
(19) Install the overdrive clutch wavy snap-ring
with the two tabbed ears into the input clutch
retainer.
(20) Install the OD/reverse reaction plate into the
input clutch retainer. The reaction plate is non-direc-
tional (Fig. 86).
(21) Install the OD/reverse reaction plate flat
snap-ring into the input clutch retainer.
(22) Mount a dial indicator to the assembly and
zero the indicator against the OD/reverse reactionplate (Fig. 89). Apply 20 psi of air pressure to the
overdrive clutch and record the dial indicator read-
ing. Measure and record OD clutch pack measure-
ment in four (4) places, 90É apart. Take average of
four measurements and compare with OD clutch
pack clearance specification.Verify that the clutch
clearance is 1.103-1.856 mm (0.043-0.073 in.). The
reaction plate is not selective. If the clutch clearance
is not within specification, replace the reaction plate
along with all the friction and steel discs.
(23) Install the reverse clutch pack into the input
clutch retainer (Fig. 86).
Fig. 86 Input Clutch Assembly - Part II
1 - BEARING NUMBER 3 10 - SNAP-RING (SELECT)
2 - OD HUB/SHAFT 11 - PLATE
3 - SNAP-RING (WAVE) 12 - DISC
4 - REV/OD REACTION PLATE 13 - OD CLUTCH
5 - BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
9 - REVERSE REACTION PLATE 18 - BEARING NUMBER 2
21 - 380 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
INPUT CLUTCH ASSEMBLY (Continued)

INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 52)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 52). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
(6) Align and install low range/input gear assem-
bly in front case (Fig. 53). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 54).
(8) Install a new input gear seal using Installer
8841 and Handle C-4171.
Fig. 52 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 53 Install Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 54 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
DRTRANSFER CASE - NV241 GENII 21 - 431
TRANSFER CASE - NV241 GENII (Continued)