1998 DODGE RAM 1500 check transmission fluid

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)

AUTOMATIC TRANSMISSION - 45RFE/545RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 45RFE/545RFE
DESCRIPTION........................312
OPERATION..........................313
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................314
DIAGNOSIS AND TESTING -
PRELIMINARY.......................314
DIAGNOSIS AND TESTING - ROAD
TESTING...........................314
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................316
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION....317
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................318
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................318
REMOVAL............................318
DISASSEMBLY........................320
CLEANING...........................326
INSPECTION.........................326
ASSEMBLY...........................326
INSTALLATION........................333
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............337
SPECIFICATIONS
TRANSMISSION.....................358
SPECIAL TOOLS
RFE TRANSMISSION.................359
4C RETAINER/BULKHEAD
DISASSEMBLY........................362
ASSEMBLY...........................363
ADAPTER HOUSING SEAL
REMOVAL............................364
INSTALLATION........................364
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION........................364
OPERATION..........................364
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......364
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................365
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............366
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................366DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................366
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................366
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............367
STANDARD PROCEDURE - TRANSMISSION
FILL...............................368
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................368
REMOVAL............................369
INSTALLATION........................370
ADJUSTMENTS
GEARSHIFT CABLE..................370
HOLDING CLUTCHES
DESCRIPTION........................371
OPERATION..........................372
INPUT CLUTCH ASSEMBLY
DESCRIPTION........................373
OPERATION..........................373
DISASSEMBLY........................374
ASSEMBLY...........................378
INPUT SPEED SENSOR
DESCRIPTION........................382
OPERATION..........................382
REMOVAL............................382
INSTALLATION........................382
LINE PRESSURE (LP) SENSOR
DESCRIPTION........................382
OPERATION..........................383
REMOVAL............................383
INSTALLATION........................383
LOW/REVERSE CLUTCH
DISASSEMBLY........................384
CLEANING...........................385
INSPECTION.........................385
ASSEMBLY...........................385
OIL PUMP
DESCRIPTION........................386
OPERATION..........................386
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK.....................387
DISASSEMBLY........................388
CLEANING...........................390
INSPECTION.........................390
ASSEMBLY...........................390
OIL PUMP FRONT SEAL
REMOVAL............................391
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 311

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.
21 - 314 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST
An accurate tachometer and pressure test gauges
are required. Test Gauge C-3293-SP has a 300 psi
range and is used at all locations where pressures
exceed 100 psi.
Pressure Test Port Locations
Only two pressure ports are supplied on the trans-
mission case. The torque converter clutch apply and
release ports are located on the right side of the
transmission case (Fig. 2).
To determine the line pressure, there are two avail-
able methods. The DRBtscan tool can be used to
read line pressure from the line pressure sensor. The
second method is to install Line Pressure Adapter
8259 (Fig. 4) into the transmission case and then
install the pressure gauge and the original sensor
into the adapter. This will allow a comparison of the
DRBtreadings and the gauge reading to determine
the accuracy of the line pressure sensor. The DRBt
line pressure reading should match the gauge read-
ing within  10 psi.
In order to access any other pressure tap locations,
the transmission oil pan must be removed, the pres-
sure port plugs removed and Valve Body Pressure
Tap Adapter 8258-A (Fig. 5) installed. The extensions
supplied with Adapter 8258-A will allow the installa-
tion of pressure gauges to the valve body. Refer to
(Fig. 3) for correct pressure tap location identifica-
tion.
TEST PROCEDURE
All pressure readings should be taken with the
transmission fluid level full, transmission oil at the
normal operating temperature, and the engine at
1500 rpm. Check the transmission for proper opera-
tion in each gear position that is in question or if a
specific element is in question, check the pressure
readings in at least two gear positions that employ
that element. Refer to the Hydraulic Schematics at
the rear of this section to determine the correct pres-
sures for each element in a given gear position.
Fig. 2 Torque Converter Pressure Locations
1 - TCC RELEASE
2 - TO COOLER
3 - TCC APPLY
4 - FROM COOLER
5 - LINE PRESSURE SENSOR
Fig. 3 Pressure Tap Locations
Fig. 4 Line Pressure Adapter 8259
1 - LINE PRESSURE SENSOR PORT
2 - LINE PRESSURE SENSOR
3 - TOOL 8259
4 - PRESSURE TAP
21 - 316 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

o-ring is properly installed and is free of any debris.
The hub must be smooth to avoid damaging pump
seal at installation.
(2) If a replacement transmission is being
installed, transfer any components necessary, such as
the manual shift lever and shift cable bracket, from
the original transmission onto the replacement trans-
mission.
(3) Lubricate oil pump seal lip with transmission
fluid.
(4) Align converter and oil pump.(5) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(6) Check converter seating with steel scale and
straightedge (Fig. 53). Surface of converter lugs
should be at least 13mm (1/2 in.) to rear of straight-
edge when converter is fully seated.
(7) Temporarily secure converter with C-clamp.
(8) Position transmission on jack and secure it
with chains.
(9) Check condition of converter driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Apply a light coating of MopartHigh Temp
Grease to the torque converter hub pocket in the rear
pocket of the engine's crankshaft.
(11) Raise transmission (Fig. 54) and align the
torque converter with the drive plate and transmis-
sion converter housing with the engine block.
(12) Move transmission forward. Then raise, lower
or tilt transmission to align the converter housing
with engine block dowels.
(13) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft. Verify that no wires, or the transmission
vent hose, have become trapped between the engine
block and the transmission.
(14) Install two bolts to attach the transmission to
the engine.
(15) Install remaining torque converter housing to
engine bolts. Tighten to 68 N´m (50 ft.lbs.).
Fig. 51 Install Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 52 Install Input, Output, and Line Pressure
Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
Fig. 53 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
21 - 334 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluid
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
(1) Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
(2) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(3) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to replace contaminated converter after
repairThe use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The torque converter should also be replaced when-
ever a failure generates sludge and debris. This is
necessary because normal converter flushing proce-
dures will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transmission vent where it may be mis-
taken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level.
It is located on the right side of the engine. Be sure
to wipe all dirt from dipstick handle before removing.
The torque converter fills in both the P (PARK)
and N (NEUTRAL) positions. Place the selector lever
in P (PARK) to be sure that the fluid level check is
accurate.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.At normal operating temperature
(approximately 82 C. or 180 F.), the fluid level is cor-
rect if it is in the HOT region (cross-hatched area) on
the oil level indicator. The fluid level will be approx-
21 - 366 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR

imately at the upper COLD hole of the dipstick at
70É F fluid temperature.
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
(1) Start engine and apply parking brake.
(2) Shift the transmission into DRIVE for approxi-
mately 2 seconds.
(3) Shift the transmission into REVERSE for
approximately 2 seconds.
(4) Shift the transmission into PARK.
(5) Hook up DRBtscan tool and select transmis-
sion.
(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the
chart. (Fig. 66)
(9) Adjust transmission fluid level shown on the
dipstick according to the chart.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmission for leaks.STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper service intervals (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION).
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Place a large diameter shallow drain pan
beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to
transmission.
(4) Loosen bolts holding rear of pan to transmis-
sion.
(5) Slowly separate front of pan away from trans-
mission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolts hold-
ing pan to transmission.
(7) While holding pan level, lower pan away from
transmission.
(8) Pour remaining fluid in pan into drain pan.
(9) Remove screw holding filter to valve body (Fig.
67).
(10) Separate filter from valve body and oil pump
and pour fluid in filter into drain pan.
Fig. 66 Transmission Fluid Temperature Chart
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 367
FLUID AND FILTER (Continued)

(11) Remove and discard the oil filter seal from the
bottom of the oil pump.
(12) If replacing the cooler return filter, use Oil
Filter Wrench 8321 to remove the filter from the
transmission.
(13) Dispose of used trans fluid and filter(s) prop-
erly.
INSPECTION
Inspect bottom of pan and magnet for excessive
amounts of metal. A light coating of clutch material
on the bottom of the pan does not indicate a problem
unless accompanied by a slipping condition or shift
lag. If fluid and pan are contaminated with excessive
amounts of debris, refer to the diagnosis section of
this group.
CLEANING
(1) Using a suitable solvent, clean pan and mag-
net.
(2) Using a suitable gasket scraper, clean original
sealing material from surface of transmission case
and the transmission pan.
INSTALLATION
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(1) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.(2) Place replacement filter in position on valve
body and into the oil pump.
(3) Install screw to hold filter to valve body (Fig.
67). Tighten screw to 4.5 N´m (40 in. lbs.) torque.
(4) Install new cooler return filter onto the trans-
mission, if necessary. Torque the filter to 14.12 N´m
(125 in.lbs.).
(5) Place bead of MopartRTV sealant onto the
transmission case sealing surface.
(6) Place pan in position on transmission.
(7) Install bolts to hold pan to transmission.
Tighten bolts to 11.8 N´m (105 in. lbs.) torque.
(8) Lower vehicle and fill transmission with
MopartATF +4.
STANDARD PROCEDURE - TRANSMISSION
FILL
To avoid overfilling transmission after a fluid
change or overhaul, perform the following procedure:
(1) Remove dipstick and insert clean funnel in
transmission fill tube.
(2) Add following initial quantity of MopartAT F
+4 to transmission:
(a) If only fluid and filter were changed, add10
pints (5 quarts)of ATF +4 to transmission.
(b) If transmission was completely overhauled
and the torque converter was replaced or drained,
add24 pints (12 quarts)of ATF +4 to transmis-
sion.
(3) Check the transmission fluid (Refer to 21 -
TRANSMISSION/AUTOMATIC - RFE/FLUID -
STANDARD PROCEDURE) and adjust as required.
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE
(1) Engine starts must be possible with shift lever
in PARK or NEUTRAL positions only. Engine starts
must not be possible in any other gear position.
(2) With the shift lever in the:
(a) PARK position - Apply upward force on the
shift arm and remove pressure. Engine starts must
be possible.
(b) PARK position - Apply downward force on
the shift arm and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.
(d) NEUTRAL position - Engine running and
brakes applied, apply upward force on the shift
arm. Transmission shall not be able to shift from
neutral to reverse.
Fig. 67 Transmission Filters - 4X4 Shown
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
21 - 368 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
FLUID AND FILTER (Continued)