2002 DODGE RAM automatic transmission fluid

(4) Lubricate o-ring on pressure sensor with trans-
mission fluid.
(5) Align pressure sensor to bore in governor body.
(6) Push pressure sensor into governor body.
(7) Lubricate o-ring, on pressure solenoid, with
transmission fluid.
(8) Align pressure solenoid to bore in governor
body (Fig. 82).
(9) Push solenoid into governor body.(10) Place solenoid retainer in position on governor
(Fig. 83).
(11) Install screws to hold pressure solenoid
retainer to governor body.
(12) Engage wire connectors into pressure sensor
and solenoid (Fig. 84).
(13) Install transmission fluid pan and (new) filter.
(14) Lower vehicle and road test to verify repair.
Fig. 80 Governor Body and Gasket
1 - GOVERNOR BODY
2 - GASKET
Fig. 81 Governor Body and Gasket
1 - GOVERNOR BODY
2 - GASKET
Fig. 82 Pressure Solenoid and O-ring
1 - PRESSURE SOLENOID
2 - O-RING
3 - GOVERNOR
Fig. 83 Pressure Solenoid Retainer
1 - PRESSURE SOLENOID RETAINER
2 - GOVERNOR
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 155
ELECTRONIC GOVERNOR (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 two primary causes.
(1) 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.
(2) 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 reverse flush cooler and lines after
repair
²failure to replace contaminated converter after
repair
The 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 transmission cooler and lines should be
reverse flushed whenever a malfunction generates
sludge and/or debris. The torque converter should
also be replaced at the same time.
Failure to flush the cooler and lines will result in
recontamination. Flushing applies to auxiliary coolers
as well. The torque converter should also be replaced
whenever a failure generates sludge and debris. This is
necessary because normal converter flushing procedures
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.
Fig. 88 Installing Overdrive Housing Seal
1 - SPECIAL TOOL C-3995-A OR C-3972-A
2 - SPECIAL TOOL C-4471
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 157
EXTENSION HOUSING SEAL (Continued)

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.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transmission recondition is
needed. Be sure to examine the fluid on the dipstick
closely. If there is any doubt about its condition,
drain out a sample for a double check.
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.
Fluid level is checked with the engine running at
curb idle speed, the transmission in NEUTRAL and
the transmission fluid at normal operating tempera-
ture.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.
The transmission fluid level can be checked two
ways.
PROCEDURE ONE
(1) Transmission fluid must be at normal operat-
ing temperature for accurate fluid level check. Drive
vehicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82ÉC (180ÉF).
(2) Position vehicle on level surface.
(3) Start and run engine at curb idle speed.
(4) Apply parking brakes.
(5) Shift transmission momentarily into all gear
ranges. Then shift transmission back to NEUTRAL.
(6) Clean top of filler tube and dipstick to keep
dirt from entering tube.
(7) Remove dipstick (Fig. 89) and check fluid level
as follows:
(a) Correct acceptable level is in crosshatch area.
(b) Correct maximum level is to MAX arrow
mark.
(c) Incorrect level is at or below MIN line.
(d)
If fluid is low, add only enough MopartATF +4,
type 9602, to restore correct level. Do not overfill.
PROCEDURE TWO
(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 engine.(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the
figure. (Fig. 90)
(9) Adjust transmission fluid level shown on the
dipstick according to the figure.
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). The service fluid fill after a
filter change is approximately 3.8 liters (4.0 quarts).
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 (Fig. 91).
(4) Loosen bolts holding rear of pan to transmis-
sion.
(5) Slowly separate front of pan and gasket away
from transmission allowing the fluid to drain into
drain pan.
(6) Hold up pan and remove remaining bolt hold-
ing pan to transmission.
(7) While holding pan level, lower pan and gasket
away from transmission.
(8) Pour remaining fluid in pan into drain pan.
(9) Remove screws holding filter to valve body
(Fig. 92).
(10) Separate filter from valve body and pour fluid
in filter into drain pan.
(11) Dispose of used trans fluid and filter properly.
Fig. 89 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
21 - 158 AUTOMATIC TRANSMISSION - 46REBR/BE
FLUID AND FILTER (Continued)

Fig. 90 46RE Fluid Fill Graph
Fig. 91 Transmission Pan
1 - TRANSMISSION
2 - GASKET
3-PAN
Fig. 92 Transmission Filter
1 - TRANSMISSION
2 - FILTER
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 159
FLUID AND FILTER (Continued)

INSTALLATION
(1) Position a new transmission oil filter onto the
valve body.
(2) Install the screws to hold the filter to the valve
body. Tighten the screws to 4 N´m (35 in.lbs.).
(3) Clean the gasket surfaces of the transmission
oil pan and transmission pan rail.
NOTE: The transmission pan oil gasket is reusable.
Inspect the sealing surfaces of the gasket. If the
sealing ribs on both surfaces appear to be in good
condition, clean the gasket of any foreign material
and reinstall.
(4) Position the oil pan gasket onto the oil pan.
(5) Position the oil pan and gasket onto the trans-
mission and install several bolts to hold the pan and
gasket to the transmission.
(6) Install the remainder of the oil pan bolts.
Tighten the bolts to 13.6 N´m (125 in.lbs.).
(7) Lower vehicle and fill transmission. (Refer to
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC/
FLUID - STANDARD PROCEDURE)
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, type 9602, to transmission:
(a) If only fluid and filter were changed, add3
pints (1-1/2 quarts)of ATF +4 to transmission.
(b) If transmission was completely overhauled,
torque converter was replaced or drained, and
cooler was flushed, add12 pints (6 quarts)of ATF
+4 to transmission.
(3) Apply parking brakes.
(4) Start and run engine at normal curb idle
speed.
(5) Apply service brakes, shift transmission
through all gear ranges then back to NEUTRAL, set
parking brake, and leave engine running at curb idle
speed.
(6) Remove funnel, insert dipstick and check fluid
level. If level is low,add fluid to bring level to
MIN mark on dipstick.Check to see if the oil level
is equal on both sides of the dipstick. If one side is
noticably higher than the other, the dipstick has
picked up some oil from the dipstick tube. Allow the
oil to drain down the dipstick tube and re-check.
(7) Drive vehicle until transmission fluid is at nor-
mal operating temperature.(8) With the engine running at curb idle speed, the
gear selector in NEUTRAL, and the parking brake
applied, check the transmission fluid level.
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fluid to bring level up to MAX arrow
mark.
When fluid level is correct, shut engine off, release
park brake, remove funnel, and install dipstick in fill
tube.
FRONT CLUTCH
DESCRIPTION
The front clutch assembly (Fig. 93) is composed of
the front clutch retainer, pressure plate, clutch
plates, driving discs, piston, piston return spring,
return spring retainer, and snap-rings. The front
clutch is the forward-most component in the trans-
mission geartrain and is directly behind the oil pump
and is considered a driving component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between
the clutch retainer and piston. The fluid pressure is
provided by the oil pump, transferred through the
control valves and passageways, and enters the
clutch through the hub of the reaction shaft support.
With pressure applied between the clutch retainer
and piston, the piston moves away from the clutch
retainer and compresses the clutch pack. This action
applies the clutch pack, allowing torque to flow
through the input shaft into the driving discs, and
into the clutch plates and pressure plate that are
lugged to the clutch retainer. The waved snap-ring is
used to cushion the application of the clutch pack.
When pressure is released from the piston, the
spring returns the piston to its fully released position
and disengages the clutch. The release spring also
helps to cushion the application of the clutch assem-
bly. When the clutch is in the process of being
released by the release spring, fluid flows through a
vent and one-way ball-check-valve located in the
clutch retainer. The check-valve is needed to elimi-
nate the possibility of plate drag caused by centrifu-
gal force acting on the residual fluid trapped in the
clutch piston retainer.
21 - 160 AUTOMATIC TRANSMISSION - 46REBR/BE
FLUID AND FILTER (Continued)

INSPECTION
Inspect the front clutch components. Replace the
clutch discs if warped, worn, scored, burned or
charred, the lugs are damaged, or if the facing is
flaking off. Replace the steel plates and reaction
plate if heavily scored, warped, or broken. Be sure
the driving lugs on the discs and plate are also in
good condition. The lugs must not be bent, cracked or
damaged in any way.
Replace the piston springs and spring retainer if
either are distorted, warped or broken.
Check the lug grooves in the clutch piston retainer.
The steel plates should slide freely in the slots.
Replace the piston retainer if the grooves are worn or
damaged. Also check action of the check ball in the
piston retainer. The ball must move freely and not
stick.
Replace the retainer bushing if worn, scored, or
there is any doubt about bushing condition.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.
Check the clutch piston check ball. The ball should
be securely in place. Replace the piston if the ball is
missing, or seized in place.
ASSEMBLY
NOTE: The 46RE transmission uses three plates
and discs for the front clutch.
(1) Mount Bushing Installer SP-5511 on tool han-
dle (Fig. 97).
(2) Slide new bushing onto installer tool and start
bushing into retainer.
(3) Tap new bushing into place until installer tool
bottoms against clutch retainer.
(4) Remove installer tools and clean retainer thor-
oughly.
(5) Soak clutch discs in transmission fluid.
(6) Install new inner piston seal onto the outer
diameter of the clutch retainer inner hub.
(7) Install new outer seal onto the clutch piston.
Be sure seal lips of both seals face the interior of the
retainer.
(8) Lubricate new inner and outer piston seals
with Ru-GlydeŸ, or MopartDoor Ease.
(9) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.015 - 0.020 in. thick), can be
used to guide seals into place if necessary.
Fig. 95 Front Clutch Components
1 - INNER PISTON SEAL 7 - CLUTCH DISCS
2 - CLUTCH PISTON 8 - RETAINER SNAP-RING
3 - CLUTCH PISTON SPRING RETAINER 9 - CLUTCH PISTON SPRINGS (9)
4 - CLUTCH PLATES 10 - OUTER PISTON SEAL
5 - CLUTCH PACK SNAP-RING (WAVED) 11 - FRONT CLUTCH RETAINER
6 - REACTION PLATE
21 - 162 AUTOMATIC TRANSMISSION - 46REBR/BE
FRONT CLUTCH (Continued)

OIL PUMP
DESCRIPTION
The oil pump (Fig. 105) is located in the pump
housing inside the bell housing of the transmission
case. The oil pump consists of an inner and outer
gear, a housing, and a reaction shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suction
at the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring the oil pump output volume will deter-
mine if sufficient oil flow to the transmission oil
cooler exists, and whether or not an internal trans-
mission failure is present.
Verify that the transmission fluid is at the proper
level. Refer to the Fluid Level Check procedure in
this section. If necessary, fill the transmission to the
proper level with MopartATF +4, type 9602, Auto-
matic Transmission Fluid.
(1) Disconnect theTo coolerline at the cooler
inlet and place a collecting container under the dis-
connected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
Fig. 105 Oil Pump Assembly
1 - OIL SEAL 7 - BOLTS (6)
2 - VENT BAFFLE 8 - #1 THRUST WASHER (SELECTIVE)
3 - OIL PUMP BODY 9 - INNER GEAR
4 - GASKET 10 - OUTER GEAR
5 - REACTION SHAFT SUPPORT 11 - ªOº RING
6 - SEAL RINGS
21 - 166 AUTOMATIC TRANSMISSION - 46REBR/BE

(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If one quart of transmission fluid is collected in
the container in 20 seconds or less, oil pump flow vol-
ume is within acceptable limits. If fluid flow is inter-
mittent, or it takes more than 20 seconds to collect
one quart of fluid, refer to the Hydraulic Pressure
tests in this section for further diagnosis.
(4) Re-connect theTo coolerline to the transmis-
sion cooler inlet.
(5) Refill the transmission to proper level.
DISASSEMBLY
(1) Mark position of support in oil pump body for
assembly alignment reference. Use scriber or paint to
make alignment marks.
(2) Place pump body on two wood blocks.
(3) Remove reaction shaft support bolts and sepa-
rate support from pump body (Fig. 106).
(4) Remove pump inner and outer gears (Fig. 107).
(5) Remove o-ring seal from pump body (Fig. 108).
Discard seal after removal.
(6) Remove oil pump seal with Remover Tool
C-3981. Discard seal after removal.
OIL PUMP BUSHING REMOVAL
(1) Position pump housing on clean, smooth sur-
face with gear cavity facing down.
(2) Remove bushing with Tool Handle C-4171 and
Bushing Remover SP-3550 (Fig. 109).
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushing Remover SP-5301 (Fig. 110).
(2) Hold cup tool firmly against reaction shaft.
Thread remover tool into bushing as far as possible
by hand.
(3) Using wrench, thread remover tool an addi-
tional 3-4 turns into bushing to firmly engage tool.
(4) Tighten tool hex nut against cup tool to pull
bushing from shaft. Clean all chips from shaft and
support after bushing removal.
Fig. 106 Reaction Shaft Support
1 - OIL PUMP
2 - REACTION SHAFT SUPPORT
Fig. 107 Pump Gears
1 - GEAR BORE
2 - PUMP BODY
3 - INNER GEAR
4 - OUTER GEAR
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 167
OIL PUMP (Continued)