1998 DODGE RAM 1500 vin

(6) Release press load slowly and completely (Fig.
137).
(7) Remove Special Tool 6227-1. Then remove
clutch pack from hub (Fig. 137). Note the orientation
of the clutch discs. The clutch pack consists of 23 sin-
gle-sided discs and they must be installed in the
same orientation as they were removed.
GEARTRAIN
(1) Remove direct clutch hub and spring (Fig. 138).
(2) Remove sun gear and spring plate. Then
remove planetary thrust bearing and planetary gear
(Fig. 139).
Fig. 137 Direct Clutch Pack Removal
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH HUB
3 - DIRECT CLUTCH PACK
Fig. 138 Direct Clutch Hub And Spring Removal
1 - DIRECT CLUTCH SPRING
2 - DIRECT CLUTCH HUB
Fig. 139 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1 - PLANETARY GEAR
2 - PLANETARY THRUST BEARING
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
DRAUTOMATIC TRANSMISSION - 48RE 21 - 223
OVERDRIVE UNIT (Continued)

INSTALLATION
(1) Be sure overdrive unit Alignment Tool 6227-2
is fully seated before moving unit. If tool is not
seated and gear splines rotate out of alignment, over-
drive unit will have to be disassembled in order to
realign splines.
(2) If overdrive piston retainer was not removed
during service and original case gasket is no longer
reusable, prepare new gasket by trimming it.
(3) Cut out old case gasket around piston retainer
with razor knife (Fig. 176).
(4) Use old gasket as template and trim new gas-
ket to fit.
(5) Position new gasket over piston retainer and
on transmission case. Use petroleum jelly to hold
gasket in place if necessary. Do not use any type of
sealer to secure gasket. Use petroleum jelly only.
(6) Install selective spacer on intermediate shaft, if
removed. Spacer goes in groove just rearward of
shaft rear splines (Fig. 177).
(7) Install thrust bearing in overdrive unit sliding
hub. Use petroleum jelly to hold bearing in position.
CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.(8) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Align-
ment Tool 6227-2. Overdrive unit cannot be installed
if splines are not aligned. If splines have rotated out
of alignment, unit will have to be disassembled to
realign splines.
(9) Carefully slide Alignment Tool 6227-2 out of
overdrive planetary gear and overrunning clutch
splines.
(10) Raise overdrive unit and carefully slide it
straight onto intermediate shaft. Insert park rod into
park lock reaction plug at same time. Avoid tilting
overdrive during installation as this could cause
planetary gear and overrunning clutch splines to
rotate out of alignment. If this occurs, it will be nec-
essary to remove and disassemble overdrive unit to
realign splines.
(11) Work overdrive unit forward on intermediate
shaft until seated against transmission case.
(12) Install bolts attaching overdrive unit to trans-
mission unit. Tighten bolts in diagonal pattern to 34
N´m (25 ft-lbs).
(13) Connect the transmission speed sensor and
overdrive wiring connectors.
(14) Install the transfer case, if equipped.
(15) Align and install rear propeller shaft, if nec-
essary. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION)
Fig. 176 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 177 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
3 - INTERMEDIATE SHAFT
DRAUTOMATIC TRANSMISSION - 48RE 21 - 235
OVERDRIVE UNIT (Continued)

OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunning clutch (Fig. 178) consists of an
inner race, an outer race (or cam), rollers and
springs, and the spring retainer. The number of roll-
ers and springs depends on what transmission and
which overrunning clutch is being dealt with.
OPERATION
As the inner race is rotated in a clockwise direction
(as viewed from the front of the transmission), the
race causes the rollers to roll toward the springs,
causing them to compress against their retainer. The
compression of the springs increases the clearance
between the rollers and cam. This increased clear-
ance between the rollers and cam results in a free-
wheeling condition. When the inner race attempts to
rotate counterclockwise, the action causes the rollers
to roll in the same direction as the race, aided by the
pushing of the springs. As the rollers try to move in
the same direction as the inner race, they are
wedged between the inner and outer races due to the
design of the cam. In this condition, the clutch is
locked and acts as one unit.
DISASSEMBLY
(1) Remove the overdrive piston (Fig. 179).
(2) Remove the overdrive piston retainer bolts.
(3) Remove overdrive piston retainer.
(4) Remove case gasket.(5) Tap old cam out of case with pin punch. Insert
punch through bolt holes at rear of case (Fig. 180).
Alternate position of punch to avoid cocking cam dur-
ing removal.
(6) Clean clutch cam bore and case. Be sure to
remove all chips/shavings generated during cam
removal.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
low-reverse drum, and overdrive piston retainer in
solvent. Dry them with compressed air after clean-
ing.
Fig. 178 Overrunning Clutch
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
Fig. 179 Overdrive Piston Removal
1 - OVERDRIVE CLUTCH PISTON
2 - INTERMEDIATE SHAFT
3 - SELECTIVE SPACER
4 - PISTON RETAINER
Fig. 180 Overrunning Clutch Cam
1 - PIN PUNCH
2 - REAR SUPPORT BOLT HOLES
21 - 236 AUTOMATIC TRANSMISSION - 48REDR

(6) Install assembled puller plate and bolt (Fig.
184). Insert bolt through cam, case and adapter tool.
Be sure plate is seated squarely on cam.
(7) Hold puller plate and bolt in place and install
puller nut SP-3701 on puller bolt (Fig. 185).
(8) Tighten puller nut to press clutch cam into
case (Fig. 185). Be sure cam is pressed into case
evenly and does not become cocked.
(9) Remove clutch cam installer tools.
(10) Stake case in 14 places around clutch cam to
help secure cam in case. Use blunt punch or chisel to
stake case.
(11) Remove piston retainer from case. Cover
retainer with plastic sheeting, or paper to keep it
dust free.
(12) Clean case and cam thoroughly. Be sure any
chips/shavings generated during cam installation are
removed from case.
(13) Install new gasket at rear of transmission
case. Use petroleum jelly to hold gasket in place. Be
sure to align governor feed holes in gasket with feed
passages in case (Fig. 186). Also install gasket before
overdrive piston retainer. Center hole in gasket is
smaller than retainer and cannot be installed over
retainer.
Fig. 186 Installing/Aligning Case Gasket
1 - CASE GASKET
2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
Fig. 184 Positioning Puller Plate On Clutch Cam
1 - SPECIAL TOOL SP-3701
2 - BE SURE PLATE SP-3583-A IS SEATED SQUARELY ON CAM
Fig. 185 Pressing Overrunning Clutch Cam Into
Case
1 - SPECIAL TOOL SP-3583-A
2 - TIGHTEN NUT TO DRAW CAM INTO CASE (NUT IS PART OF
BOLT SP-3701)
3 - SPECIAL TOOL SP-5124
4 - SPECIAL TOOL SP-3701
21 - 238 AUTOMATIC TRANSMISSION - 48REDR
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

DISASSEMBLY
(1) Remove planetary snap-ring from intermediate
shaft (Fig. 193). Discard snap-ring as it is not reus-
able.
(2) Remove front planetary gear and front annulus
gear as assembly (Fig. 194).
(3) Remove front planetary gear and thrust
washer from front annulus gear (Fig. 195). Note
thrust washer position for assembly reference.
(4) Remove tabbed thrust washer from driving
shell (Fig. 196). Note washer position for assembly
reference.
Fig. 193 Removing Planetary Snap-Ring
1 - PLANETARY SNAP-RING
Fig. 194 Removing Front Planetary And Annulus
Gears
1 - DRIVING SHELL
2 - FRONT ANNULUS GEAR
3 - FRONT PLANETARY GEAR
Fig. 195 Disassembling Front Planetary And
Annulus Gears
1 - FRONT PLANETARY GEAR
2 - TABBED THRUST WASHER
3 - FRONT ANNULUS GEAR
4 - TORLON BUSHING
Fig. 196 Driving Shell Thrust Washer Removal
1 - DRIVING SHELL
2 - TABBED THRUST WASHER
3 - SUN GEAR
21 - 242 AUTOMATIC TRANSMISSION - 48REDR
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(5) Remove sun gear and driving shell as assembly
(Fig. 197).
(6) Remove tabbed thrust washer from rear plane-
tary gear (Fig. 198). Note washer position on gear for
assembly reference.
(7) Remove rear planetary gear and rear annulus
gear from intermediate shaft (Fig. 199).
(8) Remove thrust washer from rear planetary
gear (Fig. 200).
INSPECTION
Inspect the planetary gear sets and annulus gears.
The planetary pinions, shafts, washers, and retaining
pins are serviceable. However, if a pinion carrier is
damaged, the entire planetary gear set must be
replaced as an assembly.Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash-
ers if cracked, scored or worn.
Inspect the machined surfaces of the intermediate
shaft. Be sure the oil passages are open and clear.
Replace the shaft if scored, pitted, or damaged.
Inspect the sun gear and driving shell. If either
component is worn or damaged, remove the sun gear
rear retaining ring and separate the sun gear and
thrust plate from the driving shell. Then replace the
necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as
an assembly if the bushings are scored or worn. The
sun gear bushings are not serviceable. Replace the
Fig. 197 Sun Gear And Driving Shell Removal
1 - INTERMEDIATE SHAFT
2 - DRIVING SHELL
3 - SUN GEAR
Fig. 198 Rear Planetary Thrust Washer Removal
1 - SUN GEAR
2 - REAR PLANETARY THRUST WASHER
3 - DRIVING SHELL
Fig. 199 Rear Planetary And Annulus Gear Removal
1 - INTERMEDIATE SHAFT
2 - REAR ANNULUS GEAR
3 - REAR PLANETARY GEAR
Fig. 200 Rear Annulus Thrust Washer Removal
1 - REAR ANNULUS GEAR
2 - THRUST WASHER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 243
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

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)