2003 DODGE RAM Service Repair Manual

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Page 2065 of 2895

DODGE RAM 2003 Service Repair Manual (4) Remove thrust bearing from overrunning
clutch hub.
(5) Remove overrunning clutch from hub.
(6) Mark position of annulus gear and direct clutch
drum for assembly alignment reference (Fig. 160).
Use

Page 2066 of 2895

DODGE RAM 2003 Service Repair Manual (10) Remove snap-ring that secures annulus gear
on output shaft (Fig. 164). Use two screwdrivers to
unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig.
1

(10) Remove snap-ring that secures annulus gear
on output shaft (Fig. 164). Use two screwdrivers to
unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig.
165). 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.
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 dam-
aged.
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.
Fig. 164 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 165 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 227
OVERDRIVE UNIT (Continued)

Page 2067 of 2895

DODGE RAM 2003 Service Repair Manual 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

Page 2068 of 2895

DODGE RAM 2003 Service Repair Manual (6) Slide clutch drum forward and install inner
retaining ring (Fig. 169).
(7) Install rear bearing and snap ring on output
shaft (Fig. 170). Be sure locating ring groove in bear-
ing is toward rear.

Page 2069 of 2895

DODGE RAM 2003 Service Repair Manual (11) Install planetary gear in annulus gear (Fig.
173). Be sure planetary pinions are fully seated in
annulus gear before proceeding.
(12) Coat planetary thrust bearing and bearing
contact surface of

Page 2070 of 2895

DODGE RAM 2003 Service Repair Manual (17) Install direct clutch spring (Fig. 177). Be sure
spring is properly seated on spring plate.
NOTE: The direct clutch in a 46RE transmission
uses 8 clutch discs.
(18) Assemble and install direct cl

Page 2071 of 2895

DODGE RAM 2003 Service Repair Manual (c) Install first clutch disc followed by a steel
plate until all discs and plates have been installed.
(d) Install pressure plate. This is last clutch
pack item to be installed. Be sure plate is inst

(c) Install first clutch disc followed by a steel
plate until all discs and plates have been installed.
(d) Install pressure plate. This is last clutch
pack item to be installed. Be sure plate is installed
with shoulder side facing upward (Fig. 180).
(19) Install clutch hub and clutch pack on direct
clutch spring (Fig. 181). Be sure hub is started on
sun gear splines before proceeding.WARNING: THE NEXT STEP IN GEARTRAIN ASSEM-
BLY INVOLVES COMPRESSING THE DIRECT CLUTCH
HUB AND SPRING. IT IS EXTREMELY IMPORTANT
THAT PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXIMATELY
830 POUNDS. USE COMPRESSOR TOOL C-6227-1
AND A HYDRAULIC-TYPE SHOP PRESS WITH A MINI-
MUM RAM TRAVEL OF 6 INCHES. THE PRESS MUST
ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR
DOWN AS REQUIRED. RELEASE CLUTCH SPRING
TENSION SLOWLY AND COMPLETELY TO AVOID PER-
SONAL INJURY.
(20) Position Compressor Tool 6227-1 on clutch
hub.
(21) Compress clutch hub and spring just enough
to place tension on hub and hold it in place.
(22) Slowly compress clutch hub and spring. Com-
press spring and hub only enough to expose ring
grooves for clutch pack snap ring and clutch hub
retaining ring.
(23) Realign clutch pack on hub and seat clutch
discs and plates in clutch drum.
(24) Install direct clutch pack snap ring (Fig. 182).
Be very sure snap ring is fully seated in clutch drum
ring groove.
(25) Install clutch hub retaining ring (Fig. 183). Be
very sure retaining ring is fully seated in sun gear
ring groove.
(26) Slowly release press ram, remove compressor
tools and remove geartrain assembly.
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.
Fig. 180 Correct Position Of Direct Clutch
1 - DIRECT CLUTCH PRESSURE PLATE
2 - CLUTCH PACK
3 - BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
Fig. 181 Direct Clutch Pack And Clutch Hub
Installation
1 - CLUTCH HUB
2 - DIRECT CLUTCH PACK
3 - CLUTCH DRUM
Fig. 182 Direct Clutch Pack Snap-Ring Installation
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH PACK SNAP-RING
21 - 232 AUTOMATIC TRANSMISSION - 46REDR
OVERDRIVE UNIT (Continued)

Page 2072 of 2895

DODGE RAM 2003 Service Repair Manual (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. 184). Be sure pin is
seated in h

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