2003 DODGE RAM automatic transmission fluid

3-4 ACCUMULATOR
(1) Lubricate accumulator piston, seals and hous-
ing piston bore with clean transmission fluid (Fig.
308).
(2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end plate on housing.
TRANSFER PLATE
(1) Install rear clutch and rear servo check balls in
transfer plate (Fig. 309).
(2) Install filter screen in upper housing separator
plate (Fig. 310).
(3) Align and position upper housing separator
plate on transfer plate (Fig. 311).
(4) Install brace plate (Fig. 311). Tighten brace
attaching screws to 4 N´m (35 in. lbs.) torque.
(5) Install remaining separator plate attaching
screws. Tighten screws to 4 N´m (35 in. lbs.) torque.
Fig. 308 3-4 Accumulator and Housing
1 - ACCUMULATOR PISTON
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
Fig. 309 Rear Clutch And Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
Fig. 310 Separator Plate Filter Screen Installation
1 - UPPER HOUSING SEPARATOR PLATE
2 - FILTER SCREEN
Fig. 311 Brace Plate
1 - BRACE
2 - TRANSFER PLATE
3 - SEPARATOR PLATE
DRAUTOMATIC TRANSMISSION - 48RE 21 - 479
VALVE BODY (Continued)

UPPER HOUSING VALVE AND PLUG
Refer to (Fig. 317), (Fig. 318) and (Fig. 319) to per-
form the following steps.
(1) Lubricate valves, plugs, springs with clean
transmission fluid.
(2) Assemble regulator valve line pressure sleeve,
throttle plug and spring. Insert assembly in upper
housing and install cover plate. Tighten cover plate
screws to 4 N´m (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install retainer, spring, limit valve, and 2-3
throttle plug from limit valve housing.
(6) Install limit valve housing and cover plate.
Tighten screws to 4 N´m (35 in. lbs.).
(7) Install shuttle valve as follows:
(a) Insert plastic guides in shuttle valve second-
ary spring and install spring on end of valve.
(b) Install shuttle valve into housing.
(c) Hold shuttle valve in place.
Fig. 316 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
Fig. 317 Shuttle and Boost Valve Locations
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 481
VALVE BODY (Continued)

(d) Compress secondary spring and install E-clip
in groove at end of shuttle valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(8) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N´m (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 valve governor plugs in
valve body.
(10) Install shuttle valve primary spring and
throttle plug.
(11) Align and install governor plug cover. Tighten
cover screws to 4 N´m (35 in. lbs.) torque.BOOST VALVE TUBE AND BRACE
(1) Position valve body assembly so lower housing
is facing upward (Fig. 320).
(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 320).
(4) Insert and seat each end of tube in housings.
(5) Slide tube brace under tube and into alignment
with valve body screw holes (Fig. 321).
(6) Install and finger tighten three screws that
secure tube brace to valve body housings (Fig. 321).
Fig. 318 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
21 - 482 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

(20)Install solenoid assembly and gasket. Tighten
solenoid attaching screws to 8 N´m (72 in. lbs.) torque.
(21) Verify that solenoid wire harness is properly
routed (Fig. 328). Solenoid harness must be clear of
manual lever and park rod and not be pinched
between accumulator housing and cover.
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. 329). 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. 330).
(3) Check condition of seals on accumulator piston.
Install new piston seals, if necessary.
(4) Verify that transmission range sensor isNOT
installed. Valve body cannot be installed with sensor
in place.
(5) Place valve body manual lever in low (1 posi-
tion) so ball on park lock rod will be easier to install
in sprag.
(6) Lubricate shaft of manual lever with petroleum
jelly. This will ease inserting shaft through seal in
case.
(7) Lubricate seal rings on valve body harness con-
nector with petroleum jelly.
(8) 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.
(9) Install accumulator spring and piston into case.
Then swing valve body over piston and outer spring
to hold it in place.
(10) Align accumulator piston and outer spring,
manual lever shaft and electrical connector in case.
(11) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(12) Tighten valve body bolts alternately and
evenly to 11 N´m (100 in. lbs.) torque.
(13) Install new fluid filter on valve body. Tighten
filter screws to 4 N´m (35 in. lbs.) torque.
(14) Install throttle and gearshift levers on valve
body manual lever shaft.
Fig. 329 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
Fig. 328 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
21 - 486 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

(15) Check and adjust front and rear bands if nec-
essary.
(16) Connect solenoid case connector wires.
(17) Install the transmission range sensor.
(18) Install oil pan and new gasket. Tighten pan
bolts to 17 N´m (13 ft. lbs.) torque.
(19) Lower vehicle and fill transmission with
MopartATF +4, Automatic Transmission fluid.
(20) Check and adjust gearshift and throttle valve
cables, if necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body;
²Line Pressure
²Throttle Pressure
Line and throttle pressures are interdependent
because each affects shift quality and timing. As a
result, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
LINE PRESSURE ADJUSTMENT
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 331).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa).Turning the adjusting screw counterclockwise
increases pressure while turning the screw clockwise
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
Insert Gauge Tool C-3763 between the throttle
lever cam and the kickdown valve stem (Fig. 332).
Push the gauge tool inward to compress the kick-
down valve against the spring and bottom the throt-
tle valve.
Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until the screw head
touches throttle lever tang and the throttle lever cam
touches gauge tool.
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 330 Manual Lever Shaft Seal
1 - 15/1688SOCKET
2 - SEAL
Fig. 331 Line Pressure Adjustment
1 - WRENCH
2 - 1±5/16 INCH
Fig. 332 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
DRAUTOMATIC TRANSMISSION - 48RE 21 - 487
VALVE BODY (Continued)

AUTOMATIC TRANSMISSION - 45RFE/545RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 45RFE/545RFE
DESCRIPTION........................489
OPERATION..........................490
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................491
DIAGNOSIS AND TESTING - PRELIMINARY. . 491
DIAGNOSIS AND TESTING - ROAD
TESTING...........................491
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................493
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION....494
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................495
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................495
REMOVAL............................495
DISASSEMBLY........................497
CLEANING...........................502
INSPECTION.........................503
ASSEMBLY...........................503
INSTALLATION........................510
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............513
SPECIFICATIONS
TRANSMISSION.....................534
SPECIAL TOOLS
RFE TRANSMISSION.................535
4C RETAINER/BULKHEAD
DISASSEMBLY........................538
ASSEMBLY...........................538
ADAPTER HOUSING SEAL
REMOVAL............................539
INSTALLATION........................539
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION........................540
OPERATION..........................540
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......540
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................540
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............541
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................541DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................541
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................542
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............542
STANDARD PROCEDURE - TRANSMISSION
FILL...............................544
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................544
REMOVAL............................544
INSTALLATION........................545
ADJUSTMENTS
GEARSHIFT CABLE..................546
HOLDING CLUTCHES
DESCRIPTION........................546
OPERATION..........................546
INPUT CLUTCH ASSEMBLY
DESCRIPTION........................549
OPERATION..........................549
DISASSEMBLY........................550
ASSEMBLY...........................552
INPUT SPEED SENSOR
DESCRIPTION........................558
OPERATION..........................558
REMOVAL............................559
INSTALLATION........................559
LINE PRESSURE (LP) SENSOR
DESCRIPTION........................559
OPERATION..........................559
REMOVAL............................559
INSTALLATION........................560
LOW/REVERSE CLUTCH
DISASSEMBLY........................560
CLEANING...........................561
INSPECTION.........................561
ASSEMBLY...........................561
OIL PUMP
DESCRIPTION........................562
OPERATION..........................562
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK.....................563
DISASSEMBLY........................564
CLEANING...........................566
INSPECTION.........................566
ASSEMBLY...........................566
21 - 488 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR

OIL PUMP FRONT SEAL
REMOVAL............................567
INSTALLATION........................567
OUTPUT SPEED SENSOR
DESCRIPTION........................567
OPERATION..........................567
REMOVAL............................567
INSTALLATION........................567
OVERDRIVE SWITCH
DESCRIPTION........................568
OPERATION..........................568
REMOVAL............................568
INSTALLATION........................569
PISTONS
DESCRIPTION........................569
OPERATION..........................569
PLANETARY GEARTRAIN
DESCRIPTION........................571
OPERATION..........................571
DISASSEMBLY........................573
CLEANING...........................573
INSPECTION.........................573
ASSEMBLY...........................573
SHIFT MECHANISM
DESCRIPTION........................574
OPERATION..........................574
SOLENOID SWITCH VALVE
DESCRIPTION........................574
OPERATION..........................574
SOLENOIDS
DESCRIPTION........................574OPERATION..........................575
TORQUE CONVERTER
DESCRIPTION........................575
OPERATION..........................579
REMOVAL............................580
INSTALLATION........................580
TRANSMISSION CONTROL RELAY
DESCRIPTION........................581
OPERATION..........................581
TRANSMISSION RANGE SENSOR
DESCRIPTION........................581
OPERATION..........................581
TRANSMISSION SOLENOID/TRS ASSEMBLY
DESCRIPTION........................582
OPERATION..........................582
REMOVAL............................583
INSTALLATION........................583
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION........................583
OPERATION..........................583
VALVE BODY
DESCRIPTION........................584
OPERATION..........................585
REMOVAL............................585
DISASSEMBLY........................586
CLEANING...........................588
INSPECTION.........................588
ASSEMBLY...........................590
INSTALLATION........................590
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.).
TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan
sealing surface (Fig. 1). Refer to this information
when ordering replacement parts. A label is attached
to the transmission case above the stamped numbers.
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 489

The label gives additional information which may
also be necessary for identification purposes.
GEAR RATIOS
The 45RFE gear ratios are:
1st .................................3.00:1
2nd.................................1.67:1
2nd Prime...........................1.50:1
3rd.................................1.00:1
4th .................................0.75:1
Reverse.............................3.00:1
GEAR RATIOS
The 545RFE gear ratios are:
1st .................................3.00:1
2nd.................................1.67:1
2nd Prime...........................1.50:1
3rd.................................1.00:1
4th .................................0.75:1
5th .................................0.67:1
Reverse.............................3.00:1
OPERATION
The 45RFE/545RFE offers full electronic control of
all automatic up and downshifts, and features real-
time adaptive closed-loop shift and pressure control.
Electronic shift and torque converter clutch controls
help protect the transmission from damage due to
high temperatures, which can occur under severe
operating conditions. By altering shift schedules, line
pressure, and converter clutch control, these controls
reduce heat generation and increase transmission
cooling.
To help reduce efficiency-robbing parasitic losses,
the transmissions includes a dual-stage transmission
fluid pump with electronic output pressure control.
Under most driving conditions, pump output pres-
sure greatly exceeds that which is needed to keep the
clutches applied. The 45RFE/545RFE pump-pressure
control system monitors input torque and adjusts the
pump pressure accordingly. The primary stage of the
pump works continuously; the second stage is
bypassed when demand is low. The control system
also monitors input and output speed and, if incipi-
ent clutch slip is observed, the pressure control sole-
noid duty cycle is varied, increasing pressure in
proportion to demand.
A high-travel torque converter damper assembly
allows earlier torque converter clutch engagement to
reduce slippage. Needle-type thrust bearings reduce
internal friction. The 45RFE/545RFE is packaged in
a one-piece die-cast aluminum case. To reduce NVH,
the case has high lateral, vertical and torsional stiff-
ness. It is also designed to maximize the benefit of
the structural dust cover that connects the bottom of
the bell housing to the engine bedplate, enhancing
overall power train stiffness. Dual filters protect the
pump and other components. A pump return filter is
added to the customary main sump filter. Indepen-
dent lubrication and cooler circuits assure ample
pressure for normal transmission operation even if
the cooler is obstructed or the fluid cannot flow due
to extremely low temperatures.
The hydraulic control system design (without elec-
tronic assist) provides the transmission with PARK,
REVERSE, NEUTRAL, SECOND, and THIRD gears,
based solely on driver shift lever selection. This
design allows the vehicle to be driven (in ªlimp-inº
mode) in the event of a electronic control system fail-
ure, or a situation that the Transmission Control
Module (TCM) recognizes as potentially damaging to
the transmission.
The TCM also performs certain self-diagnostic
functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRBtscan tool.
Fig. 1 Transmission Part And Serial Number
Location
1 - IDENTIFICATION NUMBERS (STAMPED)
21 - 490 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)