2002 DODGE RAM lock

(9) Mark annulus gear and output shaft for assem-
bly alignment reference (Fig. 145). Use punch or
scriber to mark gear and shaft.
(10) Remove snap-ring that secures annulus gear
on output shaft (Fig. 146). Use two screwdrivers to
unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig.
147). Use rawhide or plastic mallet to tap gear off
shaft.
GEAR CASE AND PARK LOCK
(1) Remove locating ring from gear case.
(2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap-ring and remove
reaction plug.
(4) Remove output shaft seal.
CLEANING
Clean the geartrain and case components with sol-
vent. Dry all parts except the bearings with com-
pressed air. Allow bearings to air dry.
Fig. 142 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 - DIRECT CLUTCH DRUM
2 - HAMMER
3 - PUNCH
Fig. 143 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
2 - DIRECT CLUTCH DRUM
3 - ANNULUS GEAR
Fig. 144 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 145 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 179
OVERDRIVE UNIT (Continued)

Do not use shop towels for wiping parts dry unless
the towels are made from a lint-free material. A suf-
ficient quantity of lint (from shop towels, cloths, rags,
etc.) could plug the transmission filter and fluid pas-
sages.
Discard the old case gasket and seals. Do not
attempt to salvage these parts. They are not reus-
able. Replace any of the overdrive unit snap-rings if
distorted or damaged.
Minor nicks or scratches on components can be
smoothed with crocus cloth. However, do not attempt
to reduce severe scoring on any components with
abrasive materials. Replace severely scored compo-
nents; do not try to salvage them.
INSPECTION
Check condition of the park lock components and
the overdrive case.
Check the bushings in the overdrive case. Replace
the bushings if severely scored or worn. Also replace
the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and
plates. Replace the discs if the facing is worn,
severely scored, or burned and flaking off. Replace
the clutch plates if worn, heavily scored, or cracked.
Check the lugs on the clutch plates for wear. The
plates should slide freely in the drum. Replace the
plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch
hub, clutch drum and clutch spring. Replace the gear,
hub and drum if worn or damaged. Replace the
spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and
hub are in good condition. The clutch plates and
discs should slide freely in these components.
Inspect the thrust bearings and spring plate.
Replace the plate if worn or scored. Replace the bear-
ings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun
gear and bushings. If either the sun gear or the
bushings are damaged, replace the gear and bush-
ings as an assembly. The gear and bushings are not
serviced separately.
The planetary carrier and pinions must be in good
condition. Also be sure the pinion pins are secure and in
good condition. Replace the carrier if worn or damaged.
Inspect the overrunning clutch and race. The race
surface should be smooth and free of scores. Replace
the overrunning clutch assembly or the race if either
assembly is worn or damaged in any way.
Replace the shaft pilot bushing and inner bushing
if damaged. Replace either shaft bearing if rough or
noisy. Replace the bearing snap-rings if distorted or
cracked.
Check the machined surfaces on the output shaft.
These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Inspect the output shaft bushings. The small bush-
ing is the intermediate shaft pilot bushing. The large
bushing is the overrunning clutch hub bushing.
Replace either bushing if scored, pitted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak direct clutch and overdrive clutch discs in
MopartATF +4, type 9602, transmission fluid. Allow
discs to soak for 10-20 minutes.
Fig. 146 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 147 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
21 - 180 AUTOMATIC TRANSMISSION - 46REBR/BE
OVERDRIVE UNIT (Continued)

(10) Install overrunning clutch in output shaft
(Fig. 154). Insert snap ring pliers in hub splines.
Expand pliers to grip hub. Then install assembly
with counterclockwise, twisting motion.
(11) Install planetary gear in annulus gear (Fig.
155). Be sure planetary pinions are fully seated in
annulus gear before proceeding.
(12) Coat planetary thrust bearing and bearing
contact surface of spring plate with generous amount
of petroleum jelly. This will help hold bearing in
place during installation.
(13) Install planetary thrust bearing on sun gear
(Fig. 156). Slide bearing onto gear and seat it against
spring plate as shown. Bearing fits one way only. If it
does not seat squarely against spring plate, remove
and reposition bearing.
(14) Install assembled sun gear, spring plate and
thrust bearing (Fig. 157). Be sure sun gear and
thrust bearing are fully seated before proceeding.
Fig. 152 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
Fig. 153 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
2 - OVERRUNNING CLUTCH
Fig. 154 Overrunning Clutch Installation
1 - CLUTCH DRUM
2 - OVERRUNNING CLUTCH ASSEMBLY
3 - EXPANDING-TYPE SNAP-RING PLIERS
4 - CLUTCH DRUM
5 - ANNULUS GEAR
6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
Fig. 155 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
21 - 182 AUTOMATIC TRANSMISSION - 46REBR/BE
OVERDRIVE UNIT (Continued)

GEAR CASE
(1) Position park pawl and spring in case and
install park pawl shaft. Verify that end of spring
with 90É bend is hooked to pawl and straight end of
spring is seated against case.
(2) Install pawl shaft retaining bolt. Tighten bolt
to 27 N´m (20 ft. lbs.) torque.
(3) Install park lock reaction plug. Note that plug
has locating pin at rear (Fig. 166). Be sure pin is
seated in hole in case before installing snap ring.
(4) Install reaction plug snap-ring (Fig. 167). Com-
press snap ring only enough for installation; do not
distort it.(5) Install new seal in gear case. Use Handle
C-4171 and Installer C-3995-A to seat seal in case.
(6) Verify that tab ends of rear bearing locating
ring extend into access hole in gear case (Fig. 168).
(7) Support geartrain on Tool 6227-1 (Fig. 169). Be
sure tool is securely seated in clutch hub.
(8) Install overdrive gear case on geartrain (Fig.
169).
Fig. 166 Reaction Plug Locating Pin And Snap-Ring
1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 - LOCATING PIN
3 - PARK LOCK REACTION PLUG
Fig. 167 Reaction Plug And Snap-Ring Installation
1 - REACTION PLUG SNAP-RING
2 - SNAP-RING PLIERS
Fig. 168 Correct Rear Bearing Locating Ring
Position
1 - CASE ACCESS HOLE
2 - TAB ENDS OF LOCATING RING
Fig. 169 Overdrive Gear Case Installation
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
21 - 186 AUTOMATIC TRANSMISSION - 46REBR/BE
OVERDRIVE UNIT (Continued)

(9) Expand front bearing locating ring with snap
ring pliers (Fig. 170). Then slide case downward until
locating ring locks in bearing groove and release
snap ring.
(10) Install locating ring access cover and gasket
in overdrive unit case (Fig. 171).
OVERDRIVE CLUTCH
NOTE: The overdrive clutch in a 46RE transmission
uses 4 clutch discs.
(1) Install overdrive clutch reaction ring first.
Reaction ring is flat with notched ends (Fig. 172).
(2) Install wave spring on top of reaction ring (Fig.
173). Reaction ring and wave ring both fit in same
ring groove. Use screwdriver to seat each ring
securely in groove. Also ensure that the ends of the
two rings are offset from each other.(3) Assemble overdrive clutch pack (Fig. 174).
(4) Install overdrive clutch reaction plate first.
NOTE: The reaction plate is the same thickness as
the pressure plate in a 46RE transmission.
(5) Install first clutch disc followed by first clutch
plate. Then install remaining clutch discs and plates
in same order.
(6) Install clutch pack pressure plate.
(7) Install clutch pack wire-type retaining ring
(Fig. 175).
INTERMEDIATE SHAFT SPACER SELECTION
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
(2) Determine correct thickness intermediate shaft
spacer as follows:
(a) Insert Special Tool 6312 through sun gear,
planetary gear and into pilot bushing in output
shaft. Be sure tool bottoms against planetary
shoulder.
Fig. 170 Seating Locating Ring In Rear Bearing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 171 Locating Ring Access Cover And Gasket
Installation
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 172 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
Fig. 173 Overdrive Clutch Wave Spring Installation
1 - WAVE SPRING
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 187
OVERDRIVE UNIT (Continued)

(b) Position Gauge Tool 6311 across face of over-
drive case (Fig. 176). Then position Dial Caliper
C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Gauge Alignment Tool 6312. Lock scale in place.
Remove dial caliper tool and note distance mea-
sured (Fig. 176).
(d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig.
177).
(e) Remove Gauge Alignment Tool 6312.
Fig. 174 46RE Overdrive Clutch Components
1 - REACTION PLATE 3 - PRESSURE PLATE
2 - CLUTCH PLATES (3) 4 - CLUTCH DISCS (4)
Fig. 175 Overdrive Clutch Pack Retaining Ring
Installation
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 176 Shaft End Play Measurement
1 - SPECIAL TOOL 6312
2 - SPECIAL TOOL 6311
3 - SPECIAL TOOL C-4962
Fig. 177 Intermediate Shaft End Play Spacer
Selection
21 - 188 AUTOMATIC TRANSMISSION - 46REBR/BE
OVERDRIVE UNIT (Continued)

OD THRUST PLATE SELECTION
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
(2) Determine correct thickness overdrive piston
thrust plate as follows:
(a) Position Gauge Tool 6311 across face of over-
drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 178).
(b) Measure distance to clutch hub thrust bear-
ing seat at four points 90É apart. Then average
measurements by adding them and dividing by 4.
(c) Select and install required thrust plate from
information in thrust plate chart (Fig. 179).
(3) Leave Alignment Tool 6227-2 in place. Tool will
keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on trans-
mission.
(4) Transmission speed sensor can be installed at
this time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.
OVERDRIVE PISTON
(1) Install new seals on overdrive piston.
(2) Stand transmission case upright on bellhous-
ing.
(3) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(4) Position Seal Guide 8114-3 on inner edge of
overdrive piston retainer.(5) Install overdrive piston in overdrive piston
retainer by:
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114±3 and
inside Guide Ring 8114±1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
(6) Install intermediate shaft spacer on intermedi-
ate shaft.
(7) Install overdrive piston thrust plate on over-
drive piston.
(8) Install overdrive piston thrust bearing on over-
drive piston.
(9) Install transmission speed sensor and O-ring
seal in overdrive case.
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. 180).
(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.
Fig. 178 Overdrive Piston Thrust Plate Measurement
1 - SPECIAL TOOL 6311
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
3 - SPECIAL TOOL C-4962
Fig. 179 Overdrive Piston Thrust Plate Selection
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 189
OVERDRIVE UNIT (Continued)

(6) Install selective spacer on intermediate shaft, if
removed. Spacer goes in groove just rearward of
shaft rear splines (Fig. 181).
(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)OVERDRIVE SWITCH
DESCRIPTION
The overdrive OFF (control) switch is located in
the shift lever arm (Fig. 182). The switch is a
momentary contact device that signals the PCM to
toggle current status of the overdrive function.
OPERATION
At key-on, overdrive operation is allowed. Pressing
the switch once causes the overdrive OFF mode to be
entered and the overdrive OFF switch lamp to be
illuminated. Pressing the switch a second time
causes normal overdrive operation to be restored and
the overdrive lamp to be turned off. The overdrive
OFF mode defaults to ON after the ignition switch is
cycled OFF and ON. The normal position for the con-
Fig. 180 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 181 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
3 - INTERMEDIATE SHAFT
Fig. 182 Overdrive Off Switch
21 - 190 AUTOMATIC TRANSMISSION - 46REBR/BE
OVERDRIVE UNIT (Continued)