2003 DODGE RAM sensor

(12) Lower valve body, rotate valve body away
from case, pull park rod out of sprag, and remove
valve body (Fig. 276).
DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Disconnect wires from governor pressure sen-
sor and solenoid.
(2) Remove screws attaching governor body and
retainer plate to transfer plate.
(3) Remove retainer plate, governor body and gas-
ket from transfer plate.
(4) Remove governor pressure sensor from gover-
nor body.(5) Remove governor pressure solenoid by pulling
it straight out of bore in governor body. Remove and
discard solenoid O-rings if worn, cut, or torn.
(6) Remove small shoulder bolt that secures sole-
noid harness case connector to 3-4 accumulator hous-
ing (Fig. 277). Retain shoulder bolt. Either tape it to
harness or thread it back into accumulator housing
after connector removal.
(7) Unhook overdrive/converter solenoid harness
from 3-4 accumulator cover plate (Fig. 278).
Fig. 277 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
2 - 3-4 ACCUMULATOR HOUSING
Fig. 278 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
Fig. 276 Valve Body
1 - VALVE BODY
2 - WIRE HARNESS
3 - PARK ROD
4 - GOVERNOR PRESSURE SOLENOID
5 - GOVERNOR PRESSURE SENSOR
DRAUTOMATIC TRANSMISSION - 48RE 21 - 465
VALVE BODY (Continued)

(8) Turn valve body over and remove screws that
attach overdrive/converter solenoid assembly to valve
body (Fig. 279).
(9) Remove solenoid and harness assembly from
valve body (Fig. 280).
(10) Remove boost valve cover (Fig. 281).
(11) Remove boost valve retainer, valve spring and
boost valve (Fig. 282).
(12) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 283).
Fig. 283 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 279 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 280 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 281 Boost Valve Cover Location
1 - BOOST VALVE HOUSING AND COVER
2 - BOOST VALVE TUBE
Fig. 282 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
21 - 466 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

3-4 ACCUMULATOR HOUSING
(1) Remove end plate from housing.
(2) Remove piston spring.
(3) Remove piston. Remove and discard piston
seals (Fig. 306).
CLEANING
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution.
Do not immerse any of the electrical components in
cleaning solution. Clean the governor solenoid and
sensor and the dual solenoid and harness assembly
by wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions.Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Wipe the governor pressure sensor and solenoid
valve with dry, lint free shop towels only. The O-rings
on the sensor and solenoid valve are the only service-
able components. Be sure the vent ports in the sole-
noid valve are open and not blocked by dirt or debris.
Replace the valve and/or sensor only when DRB scan
tool diagnosis indicates this is necessary. Or, if eitherpart has sustained physical damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of
the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
INSPECTION
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-
face. If distortion is severe or any surfaces are
heavily scored, the valve body will have to be
replaced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth
butdo not round off the edges of the valve or
plug lands.Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Fig. 306 3-4 Accumulator and Housing
1 - ACCUMULATOR PISTON
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
21 - 476 AUTOMATIC TRANSMISSION - 48REDR
VALVE BODY (Continued)

Check the two separator plates for distortion or
damage of any kind. Inspect the upper housing,
lower housing, 3-4 accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean
and clear. Check condition of the upper housing and
transfer plate check balls as well. The check balls
and ball seats must not be worn or damaged.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with
use. If the valve body functioned correctly when new,
it will continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
The only serviceable valve body components are
listed below. The remaining valve body components
are serviced only as part of a complete valve body
assembly. Serviceable parts are:
²dual solenoid and harness assembly
²solenoid gasket
²solenoid case connector O-rings and shoulder
bolt
²switch valve and spring
²pressure adjusting screw and bracket assembly
²throttle lever
²manual lever and shaft seal
²throttle lever shaft seal, washer, and E-clip
²fluid filter and screws
²detent ball and spring
²valve body screws
²governor pressure solenoid
²governor pressure sensor and retaining clip
²park lock rod and E-clipASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
LOWER HOUSING
(1) Lubricate valves, springs, and the housing
valve and plug bores with clean transmission fluid
(Fig. 307).
(2) Install 3-4 timing valve spring and valve in
lower housing.
(3) Install 3-4 quick fill valve in lower housing.
(4) Install 3-4 quick fill valve spring and plug in
housing.
(5) Install timing valve end plate. Tighten end
plate screws to 4 N´m (35 in. lbs.) torque.
DRAUTOMATIC TRANSMISSION - 48RE 21 - 477
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