2002 DODGE RAM check engine light

(24) Install shift tower onto the transmission case
and tighten bolts to 9 N´m (7 ft.lbs.).
INSTALLATION
NOTE: If installing a new transmission, use all com-
ponents supplied with the transmission. If a new
shift tower is supplied with the new transmission,
do not re-use the original shift tower.
(1) Apply a light coat of Mopar high temperature
bearing grease or equivalent to contact surfaces of
following components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans-
mission under vehicle.
(4) Raise transmission until input shaft is centered
in clutch disc hub.
(5) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(6) Work transmission forward until seated against
engine block. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(7) Install and tighten transmission-to-engine
block bolts.
(8) Install clutch slave cylinder.
(9) Connect backup light switch wires.
(10) Position transmission harness wires in clips
on transmission.(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Fill transmission with required lubricant (Fig.
98). Check lubricant level in transfer case if
equipped.
TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components.
(3) Remove support and lower vehicle.
(4) Shift transmission into third gear.
(5) Clean the mating surfaces of shift tower and
isolator plate with suitable wax and grease remover.
(6) Apply Mopar Gasket Maker or equivalent to
sealing surface of the transmission case. Do not over
apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(9) Verify shift tower, isolator plate and the shift
socket are properly aligned.
(10) Install bolts to hold the shift tower to the iso-
lator plate and the transmission case. Tighten bolts
to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install and secure transfer case on the trans-
mission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
Fig. 97 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
2 - EXTENSION HOUSING
Fig. 98 FILL PLUG
1 - FILL PLUG
21 - 78 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

(13) Disconnect gearshift rod and torque shaft
assembly from transmission.
(14) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever.
(15) On4x4models, disconnect shift rod from
transfer case shift lever.
(16) Support rear of engine with safety stand or
jack.
(17) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(18) Remove bolts securing rear support and cush-
ion to transmission and crossmember. Raise trans-
mission slightly, slide exhaust hanger arm from
bracket (Fig. 15) and remove rear support.
(19) Remove bolts attaching crossmember to frame
and remove crossmember.
(20) On4x4models, remove transfer case with
transmission jack or aid of helper.
(21) Remove all converter housing bolts.
(22) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(23) Lower transmission and remove assembly
from under the vehicle.
(24) To remove torque converter, remove C-clamp
from edge of bell housing and carefully slide torque
converter out of the transmission.DISASSEMBLY
(1) Clean exterior of transmission with suitable
solvent or pressure washer.
(2) Place transmission in vertical position.
(3) Measure the input shaft end play as follows
(Fig. 16).
(a) Attach Adapter 8266-5 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-5 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. Record the maximum travel for assembly ref-
erence
Fig. 15 Rear Support Cushion
1 - EXHAUST PIPE ARM AND BRACKET
2 - CROSSMEMBER
3 - REAR SUPPORT AND CUSHION
Fig. 16 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 115
AUTOMATIC TRANSMISSION - 46RE (Continued)

(a) Loosen locknut on each band adjusting screw
4-5 turns.
(b) Tighten both adjusting screws to 8 N´m (72
in. lbs.).
(c) Back off front band adjusting screw 2-7/8
turns.
(d) Back off rear band adjusting screw 2 turns.
(e) Hold each adjusting screw in position and
tighten locknut to 34 N´m (25 ft. lbs.) torque.
(2) Install magnet in oil pan. Magnet seats on
small protrusion at corner of pan.
(3) Position new oil pan gasket on case and install
oil pan. Tighten pan bolts to 13.6 N´m (125 in. lbs.).
(4) Install throttle valve and shift selector levers
on valve body manual lever shaft.
(5) Apply small quantity of dielectric grease to ter-
minal pins of solenoid case connector and neutral
switch.
(6) Fill transmission with recommended fluid.
Refer to Service Procedures section of this group.
INSTALLATION
(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish the hub and notches with 320/400 grit paper
and crocus cloth if necessary. The hub must be
smooth to avoid damaging pump seal at installation.
(2) Lubricate pocket in the rear oil pump seal lip
with transmission fluid.(3) Lubricate converter pilot hub of the crankshaft
with a light coating of MopartHigh Temp Grease.
(4) Align and install converter in 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. 65). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter 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) Raise transmission and align converter with
drive plate and converter housing with engine block.
(11) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
engine block dowels.
(12) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft.
(13) Install bolts attaching converter housing to
engine.
(14) Install rear support. Then lower transmission
onto crossmember and install bolts attaching trans-
mission mount to crossmember.
(15) Remove engine support fixture.
SOCKET 6984
Fig. 64 Manual Lever Shaft Seal
1 - 15/16©© SOCKET
2 - SEAL
Fig. 65 Checking Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
21 - 130 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)

ADJUSTMENT PROCEDURE
(1) Turn ignition switch to OFF position.
(2) Remove air cleaner if necessary.
(3) Disconnect cable end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Verify that transmission throttle lever is in
fully closed position. Then be sure lever on throttle
body is at curb idle position.
(5) Pry the T.V. cable lock (A) into the UP position
(Fig. 236). This will unlock the cable and allow for
readjustment.
(6) Apply just enough tension on the T.V. cable (B)
to remove any slack in the cable.Pulling too tight
will cause the T.V. lever on the transmission to
move out of its idle position, which will result
in an incorrect T.V. cable adjustment.Slide the
sheath of the T.V. cable (D) back and forth until the
centerlines of the T.V. cable end (B) and the throttle
bell crank lever (C) are aligned within one millimeter
(1mm) (Fig. 236).
(7) While holding the T.V. cable in the set position
push the T.V. cable lock (A) into the down position
(Fig. 236). This will lock the present T.V. cable
adjustment.NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(8) Reconnect the T.V. cable (B) to the throttle
bellcrank lever (C).
(9) Check cable adjustment. Verify transmission
throttle lever and lever on throttle body move simul-
taneously.
Fig. 234 Throttle Valve Cable Attachment - At
Engine
1 - THROTTLE VALVE CABLE
2 - CABLE BRACKET
3 - THROTTLE BODY LEVER
4 - ACCELERATOR CABLE
5 - SPEED CONTROL CABLE
Fig. 235 Throttle Valve Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
2 - THROTTLE VALVE CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT(1OR2)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 211
THROTTLE VALVE CABLE (Continued)

(13) Disconnect gearshift rod and torque shaft
assembly from transmission.
(14) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever.
(15) On4x4models, disconnect shift rod from
transfer case shift lever.
(16) Support rear of engine with safety stand or
jack.
(17) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(18) Remove bolts securing rear support and cush-
ion to transmission and crossmember. Raise trans-
mission slightly, slide exhaust hanger arm from
bracket (Fig. 15) and remove rear support.
(19) Remove bolts attaching crossmember to frame
and remove crossmember.
(20) On4x4models, remove transfer case with
transmission jack or aid of helper.
(21) Remove all converter housing bolts.
(22) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(23) Lower transmission and remove assembly
from under the vehicle.
(24) To remove torque converter, remove C-clamp
from edge of bell housing and carefully slide torque
converter out of the transmission.DISASSEMBLY
(1) Clean exterior of transmission with suitable
solvent or pressure washer.
(2) Place transmission in vertical position.
(3) Measure the input shaft end play as follows
(Fig. 16).
(a) Attach Adapter 8266-5 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-5 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. Record the maximum travel for assembly ref-
erence
Fig. 15 Rear Support Cushion
1 - EXHAUST PIPE ARM AND BRACKET
2 - CROSSMEMBER
3 - REAR SUPPORT AND CUSHION
Fig. 16 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
BR/BEAUTOMATIC TRANSMISSION - 47RE 21 - 287
AUTOMATIC TRANSMISSION - 47RE (Continued)

A/C Diagnosis
Condition Possible Causes Correction
2. Refrigerant flow
through the accumulator
is restricted.2. (Refer to Plumbing/Accumulator/ Removal/Installation)
in this group. Replace the restricted accumulator, if
required.
3. Refrigerant flow
through the a/c
evaporator is restricted.3. (Refer to Plumbing/A/C Evaporator/ Removal/
Installation) in this group. Replace the restricted
evaporator, if required.
4. Faulty compressor. 4. (Refer to Plumbing/A/C Compressor/ Removal/
Installation) in this group. Replace the compressor, if
required.
LOW SIDE PRESSURE
IS NORMAL OR
SLIGHTLY HIGH, AND
HIGH SIDE PRESSURE
IS TOO HIGH.1. Condenser air flow
restricted.1. Check the condenser for damaged fins, foreign objects
obstructing air flow through the condenser fins, and
missing or improperly installed air seals. Refer to Cooling
for more information on air seals. Clean, repair, or replace
components as required.
2. Inoperative cooling
fan.2. Refer to Cooling for more information. Test the cooling
fan and replace, if required.
3. Refrigerant system
overcharged.3. (Refer to Plumbing/Standard Procedure - Refrigerant
System Charge) in this group. Recover the refrigerant
from the refrigerant system. Charge the refrigerant
system to the proper level, if required.
4. Air in the refrigerant
system.4. (Refer to Plumbing/Diagnosis and Testing - Refrigerant
System Leaks) in this group. Test the refrigerant system
for leaks. Repair, evacuate and charge the refrigerant
system, if required.
5. Engine overheating. 5. Refer to Cooling for more information. Test the cooling
system and repair, if required.
LOW SIDE PRESSURE
IS TOO HIGH, AND
HIGH SIDE PRESSURE
IS TOO LOW.1. Accessory drive belt
slipping.1. Refer to Cooling for more information. Inspect the
accessory drive belt condition and tension. Tighten or
replace the accessory drive belt, if required.
2. A/C orifice tube not
installed.2. (Refer to Plumbing/A/C Orifice Tube/Diagnosis and
Testing) in this group. Replace the liquid line, if required.
3. Faulty a/c compressor. 3. (Refer to Plumbing/A/C Compressor/ Removal/
Installation) in this group. Replace the compressor, if
required.
LOW SIDE PRESSURE
IS TOO LOW, AND HIGH
SIDE PRESSURE IS
TOO HIGH.1. Restricted refrigerant
flow through the
refrigerant lines.1. (Refer to Plumbing/Caution - Refrigerant Hoses/Lines/
Tubes Precautions) in this group. Inspect the refrigerant
lines for kinks, tight bends or improper routing. Correct
the routing or replace the refrigerant line, if required.
2. Restricted refrigerant
flow through the a/c
orifice tube.2. (Refer to Plumbing/A/C Orifice Tube/Diagnosis and
Testing) in this group. Replace the liquid line, if required.
3. Restricted refrigerant
flow through the a/c
condenser.3. (Refer to Plumbing/A/C Condenser/ Removal/
Installation) in this group. Replace the restricted a/c
condenser, if required.
BR/BEHEATING & AIR CONDITIONING 24 - 5
HEATING & AIR CONDITIONING (Continued)

DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performing the following tests, refer to Cool-
ing for the procedures to check the engine coolant
level and flow, engine coolant reserve/recovery sys-
tem operation, accessory drive belt condition and ten-
sion, radiator air flow and the fan drive operation.
Also be certain that the accessory vacuum supply
line is connected at the engine vacuum source.
MAXIMUM HEATER OUTPUT
Engine coolant is delivered to the heater core
through two heater hoses. With the engine idling atnormal operating temperature, set the temperature
control knob in the full hot position, the mode control
switch knob in the floor position, and the blower
motor switch knob in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged at the HVAC housing floor
outlets. Compare the test thermometer reading to the
Temperature Reference chart.
Temperature Reference
Ambient Air Temperature15.5É C
(60É F)21.1É C
(70É F)26.6É C
(80É F)32.2É C
(90É F)
Minimum Air Temperature at
Floor Outlet62.2É C
(144É F)63.8É C
(147É F)65.5É C
(150É F)67.2É C
(153É F)
If the floor outlet air temperature is too low, refer
to Cooling to check the engine coolant temperature
specifications. Both of the heater hoses should be hot
to the touch. The coolant return heater hose should
be slightly cooler than the coolant supply heater
hose. If the return hose is much cooler than the sup-
ply hose, locate and repair the engine coolant flow
obstruction in the cooling system. Refer to Cooling
for the procedures.
An alternate method of checking heater perfor-
mance is to use a DRBIIItscan tool to monitor the
engine coolant temperature. The floor outlet air tem-
perature reading should be no more than 4.5É C (40É
F) lower than the engine coolant temperature read-
ing.
OBSTRUCTED COOLANT FLOW Possible loca-
tions or causes of obstructed coolant flow:
²Faulty water pump.
²Faulty thermostat.
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²A plugged heater core.If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is still
low, a mechanical problem may exist.
MECHANICAL PROBLEMS Possible locations or
causes of insufficient heat:
²An obstructed cowl air intake.
²Obstructed heater system outlets.
²A faulty, obstructed or improperly installed
blend door.
²A faulty blower system.
²A faulty a/c heater control.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
a/c heater control panel, the following could require
service:
²A faulty a/c heater control.
²A faulty blend door actuator.
²A faulty, obstructed or improperly installed
blend door.
²An obstructed cowl air intake.
²The engine cooling system.
Heater Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
INSUFFICIENT HEATER
OUTPUT.1. Incorrect engine
coolant level.1. Check the engine coolant level. Refer to Cooling for
the procedures.
2. Air trapped in engine
cooling system.2. Check the operation of the coolant reserve/recovery
system. Refer to Cooling for the procedures.
24 - 6 HEATING & AIR CONDITIONINGBR/BE
HEATING & AIR CONDITIONING (Continued)

(4) Thread the handle (Special Tool 6464 in Kit
6460) into the driver (Special Tool 6143 in Kit 6460)
(Fig. 12).
(5) Place the driver tool assembly into the bearing
cavity on the rotor. Make certain the outer edge of
the tool rests firmly on the rotor bearing inner race
(Fig. 13).
(6) Tap the end of the driver while guiding the
rotor to prevent binding. Tap until the rotor bottoms
against the compressor front housing hub. Listen for
a distinct change of sound during the tapping pro-
cess, to indicate the bottoming of the rotor.(7) Install the external front rotor snap ring with
snap ring pliers. The bevel side of the snap ring must
be facing outward. Press the snap ring to make sure
it is properly seated in the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(8) Install the original clutch shims on the com-
pressor shaft.
(9) Install the clutch plate. On models with the
diesel engine option, install the shaft key. Use the
shaft protector (Special Tool 6141-2 in Kit 6460) to
install the clutch plate on the compressor shaft (Fig.
14). Tap the clutch plate over the compressor shaft
until it has bottomed against the clutch shims. Lis-
ten for a distinct change of sound during the tapping
process, to indicate the bottoming of the clutch plate.
(10) Install the compressor shaft hex nut. Tighten
the nut to 14.4 N´m (10.5 ft. lbs.).
(11) Check the clutch air gap with a feeler gauge
(Fig. 15). If the air gap does not meet the specifica-
tion, add or subtract shims as required. The air gap
specification is 0.41 to 0.79 millimeter (0.016 to 0.031
inch). If the air gap is not consistent around the cir-
cumference of the clutch, lightly pry up at the mini-
mum variations. Lightly tap down at the points of
maximum variation.
Fig. 12 ROTOR INSTALLER SET
Fig. 13 ROTOR INSTALL
Fig. 14 CLUTCH PLATE INSTALL
24 - 16 CONTROLSBR/BE
A/C COMPRESSOR CLUTCH (Continued)