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Pressure Test Port Locations
Only two pressure ports are supplied on the transmis-
sion case. The torque converter clutch apply (3) and
release(1)portsarelocatedontherightsideofthe
transmission case.
To determine the line pressure, there are two available
methods. The scan tool can be used to read line pres-
sure from the line pressure sensor. The second
method is to install Line Pressure Adapter 8259 (3)
into the transmission case and then install the pres-
sure gauge and the original sensor (2) into the
adapter. This will allow a comparison of the scan tool
readings and the gauge reading to determine the
accuracy of the line pressure sensor. The scan tool
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line pressure reading should match the gauge reading within ±10 psi.
In order to access any other pressure tap locations,
the transmission oil pan must be removed, the pres-
sure port plugs removed and Valve Body Pressure Tap
Adapter 8258-A (2) installed. The extensions supplied
with Adapter 8258-A will allow the installation of pres-
sure gauges to the valve body.
Refer to the Pressure Tap Locations graphic for cor-
rect pressure tap location identification.
TEST PROCEDURE
All pressure readings should be taken with the transmission fluid level full, transmission oil at the normal operating
temperature, and the engine at 1500 rpm. Check the transmission for properoperation in each gear position that is
in question or if a specific element is in question, check the pressure readings in at least two gear positions that
employ that element. Refer to the Hydraulic Schematics at the rear of this section to determine the correct pres-
sures for each element in a given gear position.
NOTE: The 45RFE/545RFE utilizes closed loop control of pump line pressure. The pressure readings may
therefore vary greatly but should always follow line pressure.
Some common pressures that can be measured to evaluate pump and clutch performance are the upshift/downshift
pressures, garage shift pressures, and TCC pressure. The upshift/downshift pressure for all shifts are shown in
UPSHIFT PRESSURES and DOWNSHIFT PRESSURES . In-gear maximum pressure foreach gear position is
shown in IN-GEAR PRESSURES . The garageshift pressure when performing a N-R shift is 220 psi for 3.7L/4.7L
equipped vehicles and 250 psi for 5.7L equipped vehicles. The garage shiftpressure for the R-N shift is 120 psi.
The garage shift pressure for the N-1 shift is 135 psi for 3.7L/4.7L equipped vehicles and 165 psi for 5.7L equipped
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vehicles. Torque converter lock-up pressure is 120 psi for 3.7L/4.7L equipped vehicles and 125 psi for 5.7L
equipped vehicles.
UPSHIFT PRESSURES
ENGINE 1-2 2-3 2prime-3 3-4 2prime-4 2-5 3-5 4-5
5.7L150 125 125 135 135 135 135 135
3.7L/4.7L120 120 120 120 120 120 120 130
DOWNSHIFT PRESSURES
ENGINE 5-4 5-3 5-2 4-3 4-
2prime3-2 3-
2prime2prime-1 2-1 3-1
5.7L135 135 135 135 135 135 135 135 135 135
3.7L/
4.7L120 120 120 120 120 120 120 120 120 120
IN-GEAR PRESSURES
ENGINE122prime345NEUTRALREVERSE
5.7L160 135 135 135 135 135 120 250
3.7L/4.7L135 120 120 120 120 120 120 220
AIR CHECKING TRANSMISSION CLUTCH OPERATION
Air-pressure testing can be used to check transmis-
sion clutch operation. The test can be conducted with
the transmission either in the vehicle or on the work
bench, as a final check.
Air-pressure testing requires that the oil pan and valve
body be removed from the transmission. The clutch
apply passages are shown in the Air Pressure Test
Passages graphic.
NOTE: The air supply which is used must be free
ofmoistureanddirt.Useapressureof30psito
test clutch operation.
Apply air pressure at each port. If the clutch is func-
tioning, a soft thump will be heard as the clutch is
applied. The clutch application can also be felt by
touching the appropriate element while applying air
pressure. As the air pressure is released, the clutch
should also release.
CONVERTER HOUSING FLUID LEAK
When diagnosing converter housing fluid leaks, two items must be established before repair.
1. Verify that a leak condition actually exists.
2. Determined the true source of the leak.
1 - LOW REVERSE CLUTCH
2 - 4TH CLUTCH
3 - 2ND CLUTCH
4-OVERDRIVECLUTCH
5 - UNDERDRIVE CLUTCH
6 - REVERSE CLUTCH
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Some suspected converter housing fluid leaks may not be leaks at all. They may only be the result of residual fluid
in the converter housing, or excess fluid spilled during factory fill or fill after repair. Converter housing leaks have
several potential sources. Through careful observation, a leak source can be identified before removing the trans-
mission for repair. Torque converter seal leaks tend to move along the drive hub and onto the rear of the converter.
Pump cover seal leaks tend to run down the cover and the inside surface of thebellhousing.
Some leaks, or suspected leaks, may be particularly difficult to locate. If necessary, a Mopar
approved dye should
be used to locate and confirm a leak.
TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
1. Leaks at the weld joint around the outside diameter
weld.
2. Leaks at the converter hub weld.
In most cases, a torque converter which is wet from
transmission fluid indicates a leak at one of these
areas.
STANDARD PROCEDURE - ALUMINUM THREAD REPAIR
DamagedorwornthreadsinthealuminumtransmissioncaseandvalvebodycanberepairedbytheuseofHeli-
Coils™, or equivalent. This repair consists of drilling out the worn-out damaged threads. Then tap the hole with a
special Heli-Coil™ tap, or equivalent, and installing a Heli-Coil™ insert, or equivalent, into the hole. This brings the
hole back to its original thread size.
Heli-Coil™, or equivalent, tools and inserts are readily available from most automotive parts suppliers.
REMOVAL
1. Disconnect the negative battery cable.
2. Raise and support the vehicle
3. Remove any necessary skid plates. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
4. Mark propeller shaft and axle companion flanges
for assembly alignment.
5. Remove the rear propeller shaft
6. Remove the front propeller shaft, if necessary.
7. Remove the engine (1) to transmission (3) struc-
tural dust cover (2).
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8. Remove the exhaust support bracket from the rear
of the transmission.
9. Disconnect and lower or remove any necessary
exhaust components.
10. Remove the starter motor.
11. Rotate crankshaft in clockwise direction until con-
verter bolts are accessible. Then remove bolts
one at a time. Rotate crankshaft with socket
wrench on dampener bolt.
12. Disengage the output speed sensor connector
from the output speed sensor (2).
13. Disengage the input speed sensor connector from
the input speed sensor (2).
14. Disengage the transmission solenoid/TRS assem-
bly connector from the transmission solenoid/TRS
assembly (2).
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15. Disengage the line pressure sensor connector
from the line pressure sensor (2).
16. Disconnect gearshift cable (1) from transmission
manual valve lever (3).
17. Disconnect the transmission vent hose from the
transmission.
18. Support rear of engine with safety stand or jack.
19. Raise transmission slightly with service jack to
relieve load on crossmember and supports.
20. Remove bolts securing rear support and cushion
to transmission and crossmember.
21. Remove transfer case, if necessary.
22. Disconnect transmission fluid cooler lines at trans-
mission fittings and clips.
23. Remove all remaining converter housing bolts.
24. Carefully work transmission and torque converter
assembly rearward off engine block dowels.
25. Hold torque converter in place during transmission
removal.
26. Lower transmission (2) and remove assembly from under the vehicle.
27. To remove torque converter, carefully slide torque converter out of the transmission.
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DISASSEMBLY
1. Drain fluid from transmission.
2. Clean exterior of transmission with suitable solvent
or pressure washer.
3. Remove the torque converter from the transmis-
sion.
4. Remove the manual shift lever (1) from the
transmission.
5. Remove the input (3), output (1), and line pressure
sensors (2) from the transmission case.
6. Inspect the ends of the sensors for debris, which
may indicate the nature of the transmission failure.
7. Install Support Stand 8257 (1) onto the transmis-
sion case.
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8. Using Adapter 8266-1 from End-Play Tool Set 8266
(1) and Dial Indicator C-3339 (2), measure and
record the input shaft end-play.
NOTE: When measuring the input shaft end-play,
two
stopswill be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first
stopfelt when the input shaft is pulled out-
wardisthemovementoftheinputshaftinthe
input clutch housing hub. This value should not
be included in the end-play measured value and
therefore must be recorded and subtracted from
the dial indicator reading.
9. Remove the bolts holding the transmission exten-
sion/adapter housing to the transmission case.
10. Remove the extension/adapter housing from the
transmission case.
11. Using Alignment Plate 8261 (1), Adapter 8266-17
from End-Play Tool Set 8266 (2) and Dial Indicator
C-3339 (3), measure and record the output shaft
end-play.
12. Remove the bolts holding the transmission oil pan
to the transmission case.
13. Remove the transmission oil pan from the trans-
mission case.
14. Remove the primary oil filter (1) and the oil cooler
return filter (2).
15. Remove the cooler return filter bypass valve (3).