1998 DODGE RAM 1500 ECU

INSTALLATION
(1) Route the transmission end of the gearshift
cable through the opening in the dash panel (Fig.
72).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column
bracket so the retaining ears (Fig. 73) are engaged
and snap the cable eyelet onto the shift lever ball
stud.(4) Raise the vehicle.
(5) Place the transmission manual shift lever in
the ªPARKº detent (rearmost) position and rotate
prop shaft to ensure transmission is in PARK.
(6) Route the gearshift cable through the transmis-
sion mounting bracket and secure the cable by snap-
ping the cable retaining ears into the transmission
bracket and snapping the cable eyelet on the manual
shift lever ball stud.
(7) Lower vehicle.
(8) Lock the shift cable adjustment by pressing the
cable adjuster lock tab downward until it snaps into
place.
(9) Check for proper operation of the transmission
range sensor.
(10) Adjust the gearshift cable (Refer to 21 -
TRANSMISSION/AUTOMATIC/GEAR SHIFT
CABLE - ADJUSTMENTS) and BTSI mechanism
(Refer to 21 - TRANSMISSION/AUTOMATIC/
BRAKE TRANSMISSION SHIFT INTERLOCK SYS-
TEM - ADJUSTMENTS) as necessary.
ADJUSTMENTS
GEARSHIFT CABLE
Check adjustment by starting the engine in PARK
and NEUTRAL. Adjustment is CORRECT if the
engine starts only in these positions. Adjustment is
INCORRECT if the engine starts in one but not both
positions. If the engine starts in any position other
than PARK or NEUTRAL, or if the engine will not
start at all, the transmission range sensor may be
faulty.
Gearshift Adjustment Procedure
(1) Shift transmission into PARK.
(2) Release cable adjuster lock tab (underneath the
steering column) (Fig. 74) 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 PARK
detent by moving lever fully rearward. Last rearward
detent is PARK position.
(6) Verify positive engagement of transmission
park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.
(7) Snap the cable eyelet onto the transmission
manual shift lever.
Fig. 72 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 73 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
21 - 370 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
GEARSHIFT CABLE (Continued)

(7) Install Piston Guides 8504 into the input clutch
retainer (Fig. 83) and onto the input clutch hub to
guide the inner and outer underdrive piston seals
into position.
(8) Install the underdrive piston into the input
clutch retainer and over the input clutch hub (Fig.
82).
(9) Install the UD/OD balance piston return spring
pack into the input clutch retainer.
(10) Install Piston Guide 8252 into the input
clutch retainer (Fig. 84) to guide the UD/OD balance
piston seal into position inside the underdrive piston.(11) Install the UD/OD balance piston into the
input clutch retainer and the underdrive piston.
(12) Using Spring Compressor 8251, compress the
UD/OD return spring pack and secure the piston in
place with the snap-ring (Fig. 85).
(13) Install the underdrive clutch pack into the
input clutch retainer (Fig. 82).
(14) Install the UD/OD reaction plate lower flat
snap-ring (Fig. 86). The correct snap-ring can be
identified by the two tabbed ears.
(15) Install the UD/OD reaction plate into the
input clutch retainer. The reaction plate is to be
installed with the big step down.
(16) Install the UD/OD reaction plate upper
tapered snap-ring with tapered side up.
(17) Install the input clutch assembly into Input
Clutch Pressure Fixture 8260 (Fig. 87). Mount a dial
indicator to the assembly, push down on the clutch
discs and zero the indicator against the underdrive
clutch discs (Fig. 88). Apply 20 psi of air pressure to
the underdrive clutch and record the dial indicator
reading. Measure and record UD clutch pack mea-
surement in four (4) places, 90É apart. Take average
of four measurements and compare with UD clutch
pack clearance specification. The correct clutch clear-
ance is 0.84-1.54 mm (0.033-0.061 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.
(18) Install the overdrive clutch pack into the
input clutch retainer (Fig. 86). The overdrive steel
Fig. 83 Install Underdrive Piston Using Tool 8504
1 - TOOL 8504
Fig. 84 Install Balance Piston Using Tool 8252
1 - TOOL 8252
Fig. 85 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 379
INPUT CLUTCH ASSEMBLY (Continued)

control switch is in the OFF position, the clutch will
engage after the shift to third gear.
The TCM controls the torque converter by way of
internal logic software. The programming of the soft-
ware provides the TCM with control over the L/R-CC
Solenoid. There are four output logic states that can
be applied as follows:
²No EMCC
²Partial EMCC
²Full EMCC
²Gradual-to-no EMCC
NO EMCC
Under No EMCC conditions, the L/R Solenoid is
OFF. There are several conditions that can result in
NO EMCC operations. No EMCC can be initiated
due to a fault in the transmission or because the
TCM does not see the need for EMCC under current
driving conditions.
PARTIAL EMCC
Partial EMCC operation modulates the L/R Sole-
noid (duty cycle) to obtain partial torque converter
clutch application. Partial EMCC operation is main-
tained until Full EMCC is called for and actuated.
During Partial EMCC some slip does occur. Partial
EMCC will usually occur at low speeds, low load and
light throttle situations.
FULL EMCC
During Full EMCC operation, the TCM increases
the L/R Solenoid duty cycle to full ON after Partial
EMCC control brings the engine speed within thedesired slip range of transmission input speed rela-
tive to engine rpm.
GRADUAL-TO-NO EMCC
This operation is to soften the change from Full or
Partial EMCC to No EMCC. This is done at mid-
throttle by decreasing the L/R Solenoid duty cycle.
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive flats for sharp
edges, burrs, scratches, or nicks. Polish the hub and
flats with 320/400 grit paper or crocus cloth if neces-
sary. Verify that the converter hub o-ring is properly
installed and is free from debris. The hub must be
smooth to avoid damaging the pump seal at installa-
tion.
(1) Lubricate oil pump seal lip with transmission
fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or con-
verter hub o-ring while inserting torque converter
into the front of the transmission.
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 125). Surface of converter lugs
should be at least 13 mm (1/2 in.) to rear of straight-
edge when converter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle.
Fig. 124 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
21 - 404 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
TORQUE CONVERTER (Continued)

(11) Remove the transfer plate from the valve
body. Note the location of all check balls (Fig. 137).
(12) Remove the check balls from the valve body.
(13) Remove the retainers securing the solenoid
switch valve, manual valve, and the low/reverse
switch valve into the valve body and remove the
associated valve and spring. Tag each valve and
spring combination with location information to aid
in assembly. (Fig. 138)
CLEANING
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution. (Fig. 139)
Do not immerse any of the electrical components in
cleaning solution. Clean the electrical components by
wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions.Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Fig. 137 Check Ball Locations
Fig. 138 Valve Body Components
1 - SOLENOID SWITCH VALVE
2 - MANUAL VALVE
3 - LOW REVERSE SWITCH VALVE
4 - LOW REVERSE ACCUMULATOR
5 - 2ND CLUTCH ACCUMULATOR
6 - UNDERDRIVE ACCUMULATOR
7 - OVERDRIVE ACCUMULATOR
8 - 4TH CLUTCH ACCUMULATOR
9 - CHECK BALLS (7)
21 - 412 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
VALVE BODY (Continued)

Condition Possible Cause Correction
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Mark front and rear propeller shafts for assem-
bly reference.(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
DRTRANSFER CASE - NV241 GENII 21 - 417
TRANSFER CASE - NV241 GENII (Continued)

DRIVE CHAIN
Examine the drive chain and shaft bearings.
replace the chain if stretched, distorted, or if any of
the links bind. Replace the bearings if rough, or
noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 43)
FRONT CASE AND REAR CASE
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with LoctiteŸ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with HelicoilŸ stain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
(1) Remove the input shaft bearing (Fig. 44) from
the front case with suitable snap-ring pliers.
(2) Transfer the retaining ring to the new bearing
if necessary and install the bearing into the front
case.
Fig. 42 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
Fig. 43 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
Fig. 44 Remove Input Gear Bearing
1 - INPUT GEAR BEARING
2 - FRONT CASE
21 - 428 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(18) Install range lever on sector shaft (Fig. 68).
(19) Install washer and nut on sector shaft to
secure shift lever. Apply 1-2 drops MopartLock N'
Seal, or equivalent, to nut threads before installation.
Then tighten nut to 27-34 N´m (20-25 ft. lbs.) torque.
(20) Install new o-ring on detent plug (Fig. 69).
(21) Install detent plunger, spring, and plug (Fig.
70). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 71) into the
front output shaft bearing.
(2) Install the front output shaft retaining ring
(Fig. 72) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A
(4) Insert front sprocket in drive chain.
Fig. 68 Install Range Lever Nut
1 - RANGE LEVER
Fig. 69 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 71 Install Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 72 Install Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
DRTRANSFER CASE - NV241 GENII 21 - 435
TRANSFER CASE - NV241 GENII (Continued)

SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Raise and support the vehicle.
(3) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(4) Lower vehicle.
(5) Remove transfer case shifter knob cap.
(6) Remove nut holding shifter knob to shift lever.
(7) Remove shifter knob.
(8) Remove the shift boot from the shifter console.
(9) Remove the bolts securing the shifter mecha-
nism to the floor pan (Fig. 88).
(10) Separate shift lever mechanism from the vehi-
cle.
Fig. 88 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
21 - 444 TRANSFER CASE - NV241 GENIIDR