1998 DODGE RAM 1500 Shift solenoid

Fig. 305 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
21 - 300 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn valve body assembly over so accumulator
side of transfer plate is facing down.
(2) Install new O-rings on governor pressure sole-
noid and sensor.
(3) Lubricate solenoid and sensor O-rings with
clean transmission fluid.
(4) Install governor pressure sensor in governor
body.
(5) Install governor pressure solenoid in governor
body. Push solenoid in until it snaps into place in
body.
(6) Position governor body gasket on transfer
plate.
(7) Install retainer plate on governor body and
around solenoid. Be sure solenoid connector is posi-
tioned in retainer cutout.
(8) Align screw holes in governor body and trans-
fer plate. Then install and tighten governor body
screws to 4 N´m (35 in. lbs.) torque.
(9) Connect harness wires to governor pressure
solenoid and governor pressure sensor.
(10) Install fluid filter and pan.
(11) Lower vehicle.
(12) Fill transmission with recommended fluid and
road test vehicle to verify repair.
INSTALLATION
(1) Check condition of O-ring seals on valve body
harness connector (Fig. 327). Replace seals on con-
nector body if cut or worn.
(2) Check condition of manual lever shaft seal in
transmission case. Replace seal if lip is cut or worn.
Install new seal with 15/16 deep well socket (Fig.
328).
(3) Check condition of seals on accumulator piston.
Install new piston seals, if necessary.
(4) Place valve body manual lever in low (1 posi-
tion) so ball on park lock rod will be easier to install
in sprag.
(5) Lubricate shaft of manual lever with petroleum
jelly. This will ease inserting shaft through seal in
case.
(6) Lubricate seal rings on valve body harness con-
nector with petroleum jelly.
(7) Position valve body in case and work end of
park lock rod into and through pawl sprag. Turn pro-
peller shaft to align sprag and park lock teeth if nec-
essary. The rod will click as it enters pawl. Move rod
to check engagement.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.(8) Install accumulator spring and piston into case.
Then swing valve body over piston and outer spring
to hold it in place.
(9) Align accumulator piston and outer spring,
manual lever shaft and electrical connector in case.
(10) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(11) Tighten valve body bolts alternately and
evenly to 11 N´m (100 in. lbs.) torque.
(12) Install new fluid filter on valve body. Tighten
filter screws to 4 N´m (35 in. lbs.) torque.
(13) Install throttle and gearshift levers on valve
body manual lever shaft.
(14) Check and adjust front and rear bands if nec-
essary.
(15) Install the transmission range sensor (Refer
to 21 - TRANSMISSION/AUTOMATIC/TRANSMIS-
SION RANGE SENSOR - INSTALLATION).
(16) Connect solenoid case connector wires.
(17) Install oil pan and new gasket. Tighten pan
bolts to 13.6 N´m (125 in. lbs.) torque.
(18) Lower vehicle and fill transmission with
MopartATF +4, Automatic Transmission fluid.
(19) Check and adjust gearshift and throttle valve
cables, if necessary.
Fig. 327 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
DRAUTOMATIC TRANSMISSION - 48RE 21 - 309
VALVE BODY (Continued)

INSTALLATION........................391
OUTPUT SPEED SENSOR
DESCRIPTION........................391
OPERATION..........................391
REMOVAL............................391
INSTALLATION........................392
TOW/HAUL OVERDRIVE SWITCH
DESCRIPTION........................392
OPERATION..........................392
REMOVAL............................392
INSTALLATION........................393
PISTONS
DESCRIPTION........................393
OPERATION..........................393
PLANETARY GEARTRAIN
DESCRIPTION........................395
OPERATION..........................396
DISASSEMBLY........................396
CLEANING...........................396
INSPECTION.........................397
ASSEMBLY...........................397
SHIFT MECHANISM
DESCRIPTION........................398
OPERATION..........................398
SOLENOID SWITCH VALVE
DESCRIPTION........................398
OPERATION..........................398
SOLENOIDS
DESCRIPTION........................398OPERATION..........................399
TORQUE CONVERTER
DESCRIPTION........................399
OPERATION..........................403
REMOVAL............................404
INSTALLATION........................404
TRANSMISSION CONTROL RELAY
DESCRIPTION........................405
OPERATION..........................405
TRANSMISSION RANGE SENSOR
DESCRIPTION........................405
OPERATION..........................405
TRANSMISSION SOLENOID/TRS ASSEMBLY
DESCRIPTION........................406
OPERATION..........................406
REMOVAL............................407
INSTALLATION........................408
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION........................408
OPERATION..........................408
VALVE BODY
DESCRIPTION........................408
OPERATION..........................408
REMOVAL............................410
DISASSEMBLY........................410
CLEANING...........................412
INSPECTION.........................413
ASSEMBLY...........................414
INSTALLATION........................414
AUTOMATIC TRANSMISSION -
45RFE/545RFE
DESCRIPTION
The 45RFE/545RFE automatic transmissions is a
sophisticated, multi-range, electronically controlled
transmission which combines optimized gear ratios
for responsive performance, state of the art efficiency
features and low NVH. Other features include driver
adaptive shifting and three planetary gear sets to
provide wide ratio capability with precise ratio steps
for optimum driveability. The three planetary gear
sets also make available a unique alternate second
gear ratio. The primary 2nd gear ratio fits between
1st and 3rd gears for normal through-gear accelera-
tions. The alternate second gear ratio (2prime) allows
smoother 4-2 kickdowns at high speeds to provide
2nd gear passing performance over a wider highway
cruising range.
The hydraulic portion of the transmission consists
of the transmission fluid, fluid passages, hydraulic
valves, and various line pressure control components.The primary mechanical components of the trans-
mission consist of the following:
²Three multiple disc input clutches
²Three multiple disc holding clutches
²Five hydraulic accumulators
²Three planetary gear sets
²Dual Stage Hydraulic oil pump
²Valve body
²Solenoid pack
The TCM is the ªheartº or ªbrainº of the electronic
control system and relies on information from vari-
ous direct and indirect inputs (sensors, switches, etc.)
to determine driver demand and vehicle operating
conditions. With this information, the TCM can cal-
culate and perform timely and quality shifts through
various output or control devices (solenoid pack,
transmission control relay, etc.).
21 - 312 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR

(16) Install transfer case, if equipped. Tighten
transfer case nuts to 35 N´m (26 ft.lbs.).
(17) Install rear support to transmission. Tighten
bolts to 47 N´m (35 ft.lbs.).
(18) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member. Tighten clevis bracket to crossmember bolts
to 47 N´m (35 ft.lbs.). Tighten the clevis bracket to
rear 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 switch
assembly (Fig. 55) connector, input (Fig. 56) and out-
put (Fig. 57) speed sensors, and line pressure sensor
(Fig. 58). Be sure transmission harnesses are prop-
erly routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
Fig. 54 Install Transmission
1 - ENGINE
2 - TRANSMISSION
Fig. 55 Connect Transmission Solenoid
1 - TRANSMISSION
2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
Fig. 56 Connect Input Speed Sensor
1 - TRANSMISSION
2 - INPUT SPEED SENSOR
Fig. 57 Connect Output Speed Sensor
1 - TRANSMISSION
2 - OUTPUT SPEED SENSOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 335
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

ADAPTER HOUSING SEAL
REMOVAL
(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 adapter
housing of any residue or particles remaining from
the original seal.
(2) Install new oil seal in the adapter housing
using Seal Installer C-3860-A (Fig. 63). A properly
installed seal is flush to the face of the seal bore.
(3) Install the transfer case onto the transmission.
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM
DESCRIPTION
The Brake Transmission Shifter Interlock (BTSI)
(Fig. 64), is a solenoid operated system. It consists of
a solenoid permanently mounted on the gearshift
cable.
OPERATION
The system locks the shifter into the PARK position.
The interlock system is engaged whenever the ignition
switch is in the LOCK or ACCESSORY position. An
additional electrically activated feature will prevent
shifting out of the PARK position unless the brake pedalis depressed approximately one-half an inch. A magnetic
holding device in line with the park lock cable is ener-
gized when the ignition is in the RUN position. When
the key is in the RUN position and the brake pedal is
depressed, the shifter is unlocked and will move into
any position. The interlock system also prevents the
ignition switch from being turned to the LOCK or
ACCESSORY position, unless the shifter is fully locked
into the PARK position.
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK
(1) Verify that the key can only be removed in the
PARK position
(2) When the shift lever is in PARK And the shift
handle pushbutton is in the ªOUTº position, the igni-
tion key cylinder should rotate freely from OFF to
LOCK. When the shifter is in any other gear or neu-
tral position, the ignition key cylinder should not
rotate to the LOCK position.
(3) Shifting out of PARK should not be possible
when the ignition key cylinder is in the OFF posi-
tion.
(4) Shifting out of PARK should not be possible
while applying normal pushbutton force and ignition
key cylinder is in the RUN or START positions
unless the foot brake pedal is depressed approxi-
mately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the ACCESSORY
or LOCK positions.
(6)
Shifting between any gears, NEUTRAL or into
PARK may be done without depressing foot brake pedal
with ignition switch in RUN or START positions.
Fig. 63 Adapter Housing Seal Installation
1 - TOOL C-3860-A
Fig. 64 Brake Transmission Interlock Mechanism
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
21 - 364 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR

ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK
Correct cable adjustment is important to proper
interlock 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 necessary
for access to the brake transmission shift interlock.
(2) Shift the transmission into the PARK position.
(3) Pull upward on both the BTSI lock tab and the
gearshift cable lock tab (Fig. 65).
(4) Verify that the shift lever is in the PARK posi-
tion.
(5) Verify positive engagement of the transmission
park lock by attempting to rotate the propeller shaft.
The shaft will not rotate when the park lock is
engaged.
(6) Turn ignition switch to LOCK position.Be
sure ignition key cylinder is in the LOCK posi-
tion. Cable will not adjust correctly in any
other position.
(7) Ensure that the cable is free to self-adjust by
pushing cable rearward and releasing.
(8) Push the gearshift cable lock tab down until it
snaps in place.
(9) Locate the BTSI alignment hole in the bottom
of the BTSI mechanism between the BTSI lock tab
and the BTSI connector.(10) Move the BTSI assembly up or down on the
gearshift cable until an appropriate size drill bit can
be inserted into the alignment hole and through the
assembly.
(11) Push the BTSI lock tab down until it snaps
into place and remove the drill bit.
(12) Install any steering column trim previously
removed.
BTSI FUNCTION CHECK
(1) Verify removal of ignition key allowed in PARK
position only.
(2) When the shift lever is in PARK, the ignition
key cylinder should rotate freely from off to lock.
When the shifter is in any other position, the ignition
key should not rotate from off to lock.
(3) Shifting out of PARK should be possible when
the ignition key cylinder is in the off position.
(4) Shifting out of PARK should not be possible
while applying normal force, and ignition key cylin-
der is in the run or start positions, unless the foot
brake pedal is depressed approximately 1/2 inch
(12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the accessory or
lock position.
(6) Shifting between any gear and NEUTRAL, or
PARK, may be done without depressing foot brake
with ignition switch in run or start positions.
(7) Engine starts must be possible with shifter
lever in PARK or NEUTRAL positions only. Engine
starts must not be possible in any position other than
PARK or NEUTRAL.
(8) With shifter lever in the:
²PARK position - Apply upward force on the shift
arm and remove pressure. Engine starts must be
possible.
²PARK position - Apply downward force on the
shift arm and remove pressure. Engine starts must
be possible.
²NEUTRAL position - Normal position. Engine
starts must be possible.
²NEUTRAL position - Engine running and brakes
applied, apply upward force on the shift arm. Trans-
mission shall not be able to shift from neutral to
reverse.
Fig. 65 Brake Transmission Interlock Mechanism
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 365
BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM (Continued)

REMOVAL
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Disengage cable eyelet at transmission shift
lever and pull cable adjuster out of mounting bracket
(Fig. 68) or (Fig. 69).
(4) Lower the vehicle.(5) Remove the dash panel insulation pad as nec-
essary to access the gearshift cable grommet (Fig.
70).
(6) Remove grommet from the dash panel.
(7) Remove any steering column trim necessary to
access the gearshift cable and BTSI mechanism.
(8) Disconnect the BTSI wiring connector.
(9) Disconnect cable at lower column bracket and
shift lever pin and pull the cable through the dash
panel opening into the vehicle (Fig. 71).
(10) Remove gearshift cable from vehicle.
Fig. 68 Gearshift Cable at Transmission - RFE
1 - GEARSHIFT CABLE
2 - RFE TRANSMISSION
3 - MANUAL LEVER
Fig. 69 Gearshift Cable at Transmission - RE
1 - GEARSHIFT CABLE
2 - RE TRANSMISSION
3 - MANUAL LEVER
Fig. 70 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 71 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 369
GEARSHIFT CABLE (Continued)

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)