2003 DODGE RAM ECU

CAUTION: If the condition of the transmission
before the overhaul procedure caused excessive
metallic or fiber contamination in the fluid, replace
the torque converter. Fluid contamination and trans-
mission failure can result if not done.
(6) Install torque converter. Use C-clamp or metal
strap to hold converter in place for installation.
BAND ADJUSTMENT AND FINAL
(1) Adjust front and rear bands as follows:
(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 17 N´m (13 ft. 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 transmis-
sion range sensor.
(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. 69). 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.
(15) Install the rear transmission crossmember.
(16) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member.
(17) Remove engine support fixture.
(18) Install the transfer case, if equipped.
(19) Install crankshaft position sensor. (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT
POSITION SENSOR - INSTALLATION)
Fig. 69 Checking Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
DRAUTOMATIC TRANSMISSION - 46RE 21 - 173
AUTOMATIC TRANSMISSION - 46RE (Continued)

(7) Assemble Tool Handle C-4171 and Bushing
Remover SP-3629 (Fig. 103).
(8) Insert remover tool in bushing and drive bush-
ing straight out of clutch retainer.
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. 104).
(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. 103 Front Clutch Retainer Bushing
Replacement Tools
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3629
3 - SPECIAL TOOL SP-5511
4 - SPECIAL TOOL C-4171
5 - FRONT CLUTCH RETAINER
Fig. 104 Front Clutch Retainer Bushing
Replacement Tools
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3629
3 - SPECIAL TOOL SP-5511
4 - SPECIAL TOOL C-4171
5 - FRONT CLUTCH RETAINER
21 - 206 AUTOMATIC TRANSMISSION - 46REDR
FRONT CLUTCH (Continued)

(4) Raise the vehicle.
(5) Place the transmission manual shift lever in
the ªPARKº detent (rearmost) position and rotate
prop shaft to ensure transmission is in PARK.
(6) Route the gearshift cable through the transmis-
sion mounting bracket and secure the cable by snap-
ping the cable retaining ears into the transmission
bracket and snapping the cable eyelet on the manual
shift lever ball stud.
(7) Lower vehicle.
(8) Lock the shift cable adjustment by pressing the
cable adjuster lock tab downward until it snaps into
place.
(9) Check for proper operation of the transmission
range sensor.
(10) Adjust the gearshift cable and BTSI mecha-
nism as necessary.
ADJUSTMENTS
GEARSHIFT CABLE
Check adjustment by starting the engine in PARK
and NEUTRAL. Adjustment is CORRECT if the
engine starts only in these positions. Adjustment is
INCORRECT if the engine starts in one but not both
positions. If the engine starts in any position other
than PARK or NEUTRAL, or if the engine will not
start at all, the transmission range sensor may be
faulty.
Gearshift Adjustment Procedure
(1) Shift transmission into PARK.
(2) Release cable adjuster lock tab (underneath the
steering column) (Fig. 118) to unlock cable.
(3) Raise vehicle.
(4) Disengage the cable eyelet from the transmis-
sion manual shift lever.(5) Verify transmission shift lever is in PARK
detent by moving lever fully rearward. Last rearward
detent is PARK position.
(6) Verify positive engagement of transmission
park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.
(7) Snap the cable eyelet onto the transmission
manual shift lever.
(8) Lower vehicle.
(9) Lock shift cable by pressing cable adjuster lock
tab downward until it snaps into place.
(10) Check engine starting. Engine should start
only in PARK and NEUTRAL
Fig. 118 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
DRAUTOMATIC TRANSMISSION - 46RE 21 - 211
GEARSHIFT CABLE (Continued)

REACTION SHAFT SUPPORT BUSHING
(1) Place reaction shaft support upright on a clean,
smooth surface.
(2) Assemble Bushing Installer Tools C-4171 and
SP-5302. Then slide new bushing onto installer tool
(Fig. 128).
(3) Start bushing in shaft. Tap bushing into shaft
until installer tool bottoms against support flange.
(4) Clean reaction shaft support thoroughly after
bushing replacement (to remove any chips).
OIL PUMP BODY
(1) Lubricate pump gears with transmission fluid
and install them in pump body.
(2) Install thrust washer on reaction shaft support
hub. Lubricate washer with petroleum jelly or trans-
mission fluid before installation.
(3) If reaction shaft seal rings are being replaced,
install new seal rings on support hub. Lubricate seal
rings with transmission fluid or petroleum jelly after
installation. Squeeze each ring until ring ends are
securely hooked together.CAUTION: The reaction shaft support seal rings will
break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.
(4) Align and install reaction shaft support on
pump body.
(5) Install bolts attaching reaction shaft support to
pump. Tighten bolts to 20 N´m (175 in. lbs.) torque.
(6) Install new pump seal with Installer Tool
C-3860-A (Fig. 129). Use hammer or mallet to tap
seal into place.
(7) Install new o-ring on pump body. Lubricate oil
seal and o-ring with petroleum jelly.
(8) Cover pump assembly to prevent dust entry
and set aside for assembly installation.
Fig. 128 Reaction Shaft Bushing
1 - SPECIAL TOOL SP-1191
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL SP-3633
4 - SPECIAL TOOL SP-5301
5 - SPECIAL TOOL SP-5302
6 - BUSHING
7 - REACTION SHAFT
8 - BUSHING
Fig. 129 Oil Pump Seal
1 - SPECIAL TOOL C-3860-A
2 - PUMP BODY
3 - PUMP SEAL
21 - 216 AUTOMATIC TRANSMISSION - 46REDR
OIL PUMP (Continued)

(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)

(7) Support geartrain on Tool 6227-1 (Fig. 187). Be
sure tool is securely seated in clutch hub.
(8) Install overdrive gear case on geartrain (Fig.
187).
(9) Expand front bearing locating ring with snap
ring pliers (Fig. 188). 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. 189).
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. 190).
(2) Install wave spring on top of reaction ring (Fig.
191). 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.
Fig. 190 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
Fig. 191 Overdrive Clutch Wave Spring Installation
1 - WAVE SPRING
Fig. 187 Overdrive Gear Case Installation
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 188 Seating Locating Ring In Rear Bearing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 189 Locating Ring Access Cover And Gasket
Installation
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
21 - 234 AUTOMATIC TRANSMISSION - 46REDR
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. 196).
(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. 197).
(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. 198).
(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.
(6) Install selective spacer on intermediate shaft, if
removed. Spacer goes in groove just rearward of
shaft rear splines (Fig. 199).
Fig. 196 Overdrive Piston Thrust Plate Measurement
1 - SPECIAL TOOL 6311
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
3 - SPECIAL TOOL C-4962
Fig. 197 Overdrive Piston Thrust Plate Selection
21 - 236 AUTOMATIC TRANSMISSION - 46REDR
OVERDRIVE UNIT (Continued)

ASSEMBLY
(1) Temporarily install overdrive piston retainer in
case. Use 3-4 bolts to secure retainer.
(2) Align and start new clutch cam in the trans-
mission case. Be sure serrations on cam and in case
are aligned (Fig. 203). Then tap cam into case just
enough to hold it in place.
(3) Verify that cam is correctly positioned before
proceeding any further. Narrow ends of cam ramps
should be to left when cam is viewed from front end
of case (Fig. 203).
(4) Insert Adapter Tool SP-5124 into piston
retainer (Fig. 204).
(5) Assemble Puller Bolt SP-3701 and Press Plate
SP-3583-A (Fig. 205).
(6) Install assembled puller plate and bolt (Fig.
206). Insert bolt through cam, case and adapter tool.
Be sure plate is seated squarely on cam.
Fig. 206 Positioning Puller Plate On Clutch Cam
1 - SPECIAL TOOL SP-3701
2 - BE SURE PLATE SP-3583-A IS SEATED SQUARELY ON CAM
Fig. 203 Positioning Replacement Clutch Cam In
Case
1 - ALIGN SERRATIONS ON CAM AND IN CASE
2 - CLUTCH CAM
Fig. 204 Positioning Adapter Tool In Overdrive
Piston Retainer
1 - PISTON RETAINER
2 - SPECIAL TOOL SP-5124
Fig. 205 Assembling Clutch Cam Puller Bolt And
Press Plate
1 - PULLER BOLT SP-3701
2 - PRESS PLATE SP-3583-A
DRAUTOMATIC TRANSMISSION - 46RE 21 - 239
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)