Overhaul - 545RFE: Removal & Installation Dodge Durango II

INSTALLATION

Note. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. Verify that the converter hub o-ring is properly installed and is free of any debris. The hub must be smooth to avoid damaging pump seal at installation.

Scheme 1117

Scheme 1118

Scheme 1119

Scheme 1120

Scheme 1121

Scheme 1122

Scheme 1123

Scheme 1124

Scheme 1125

Scheme 1126

Scheme 1127

Scheme 1128

1. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever (3) and shift cable bracket (2), from the original transmission onto the replacement transmission.
2. Lubricate oil pump seal lip with transmission fluid.
3. Align converter and oil pump.
4. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
5. Check converter seating with steel scale and straightedge. Surface of converter lugs should be at least 13mm (1/2 in.) (1) to rear of straightedge (2) when converter is fully seated.
6. Temporarily secure converter with C-clamp.
7. Position transmission on jack and secure it with chains.
8. 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.
9. Apply a light coating of Mopar® High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
10. Raise transmission and align the torque converter with the drive plate and transmission converter housing with the engine block.
11. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine block dowels.
12. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
13. Install two bolts to attach the transmission to the engine.
14. Install remaining torque converter housing to engine bolts. Tighten to 68 N.m (50 ft.lbs.).
15. Install transfer case, if equipped. Tighten transfer case nuts to 35 N.m (26 ft.lbs.).
16. Install rear transmission crossmember (1). Tighten crossmember to frame bolts to 68 N.m (50 ft.lbs.).
17. Install rear support to transmission (2). Tighten bolts to 47 N.m (35 ft.lbs.).
18. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 N.m (35 ft.lbs.). Tighten the clevis bracket to rear support, bolt to 68 N.m (50 ft.lbs.).
19. Remove engine support fixture
20. Connect gearshift cable (1) to transmission.
21. Connect the wiring harness connector to the solenoid and pressure switch assembly (2) connector. Be sure transmission harnesses are properly routed.
22. Connect the wiring harness connector to the input speed sensor (2).
23. Connect the wiring harness connector to the output speed sensor (2).
24. Connect the wiring harness connector to the line pressure sensor (2). CAUTION: It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.
25. Install torque converter-to-driveplate bolts. Tighten bolts to 31 N.m (270 in. lbs.).
26. Install starter motor and cooler line bracket.
27. Connect cooler lines to transmission.
28. Install transmission fill tube.
29. Install exhaust components.
30. Install the structural dust cover (2) onto the transmission and the engine. (Refer to «REMOVAL»(ref-212815-S38526847082005122700000) - )
31. Align and install the front propeller shaft, if necessary. (Refer to «INSTALLATION»(ref-212736-S06869159942005122700000) - )
32. Align and install the rear propeller shaft. (Refer to «INSTALLATION»(ref-212736-S18799614722005122700000) - )
33. Adjust gearshift cable if necessary.
34. Install any skid plates (1) removed previously. (Refer to «INSTALLATION»(ref-212818-S34681251852005122700000) )
35. Lower vehicle.
36. Fill transmission with Mopar® ATF +4, Automatic Transmission Fluid.

Scheme 1129

Scheme 1130

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Scheme 1149

REMOVAL

1. Remove the transfer case from the transmission.
2. Using a screw mounted on a slide hammer, remove the adapter housing seal.

Scheme 1150

1. Clean the adapter seal bore in the adapter housing of any residue or particles remaining from the original seal.
2. Install new oil seal in the adapter housing using Seal Installer C-3860-A (1). A properly installed seal is flush to the face of the seal bore.
3. Install the transfer case onto the transmission.

1. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool.
2. Place replacement filter in position on valve body and into the oil pump.
3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 N.m (40 in. lbs.) torque.
4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 14.12 N.m (125 in.lbs.).
5. Place bead of Mopar® RTV sealant onto the transmission case sealing surface.
6. Place pan in position on transmission.
7. Install bolts to hold pan to transmission. Tighten bolts to 11.8 N.m (105 in. lbs.) torque.
8. Lower vehicle and fill transmission with Mopar® ATF +4.

1. Remove transmission from the vehicle.
2. Remove the torque converter from the transmission.
3. Using a screw mounted in a slide hammer, remove the oil pump front seal.

Scheme 1151

1. Clean seal bore of the oil pump of any residue or particles from the original seal.
2. Install new oil seal in the oil pump housing using Seal Installer C-3860-A (1).

1. Remove transmission and torque converter from vehicle.(Refer to «REMOVAL & INSTALLATION»(ref-170067-S05701105352005010300000) - )
2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission.
3. Pull the torque converter forward until the center hub clears the oil pump seal.
4. Separate the torque converter from the transmission.

Note. Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper or crocus cloth if necessary. Verify that the converter hub o-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation.

Scheme 1152

1. Lubricate oil pump seal lip with transmission fluid.
2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub o-ring while inserting torque converter into the front of the transmission.
3. Align torque converter to oil pump seal opening.
4. Insert torque converter hub into oil pump.
5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears.
6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 13 mm (1/2 in.) to rear of straightedge when converter is fully seated.
7. If necessary, temporarily secure converter with C-clamp attached to the converter housing.
8. Install the transmission in the vehicle.
9. Fill the transmission with the recommended fluid.

Note. There is enough slack in the wire to pull out the connector from the lever.

Scheme 1153

1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly.
2. Install the tow/haul overdrive off switch (3) into the connector (2)
3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1).
4. Install the tow/haul overdrive off switch retainer onto the shift lever.

Note. The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. (Refer to - DISASSEMBLY )

Scheme 1154

Scheme 1155

1. Shift transmission into PARK.
2. Raise vehicle.
3. Disconnect wires at the solenoid and pressure switch assembly connector.
4. Position drain pan under transmission oil pan.
5. Remove transmission oil pan.
6. Remove the primary oil filter (1) from valve body.
7. Remove bolts (1) attaching valve body to transmission case.
8. Lower the valve body and work the electrical connector out of transmission case.
9. Separate the valve body from the transmission.

Scheme 1156

Scheme 1157

Scheme 1158

Scheme 1159

Scheme 1160

1. Remove the bolts (1) holding the solenoid and pressure switch assembly to the valve body. Do not remove the screws on the top of the solenoid and pressure switch assembly.
2. Separate the solenoid and pressure switch assembly from the valve body.
3. Remove the screw holding the detent spring (2) onto the valve body.
4. Remove the detent spring (2) from the valve body.
5. Remove the TRS selector plate (1) from the valve body and the manual valve.
6. Remove the clutch passage seals (3) from the valve body, if necessary.
7. Remove the screws holding the accumulator cover onto the valve body.
8. Remove the accumulator springs and pistons (1, 6-9) from the valve body, Note which accumulator piston and spring belong in each location.
9. Place the valve body on the bench with the transfer plate upward. NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to prevent losing the check balls when the transfer plate is removed from the valve body.
10. Remove the screws holding the valve body to the valve body transfer plate.
11. Remove the transfer plate from the valve body. Note the location of all check balls.
12. Remove the check balls from the valve body.
13. Remove the retainers securing the solenoid switch valve (1), manual valve (2), and the low/reverse switch valve (3) from the valve body and remove the associated valve and spring. Tag each valve and spring combination with location information to aid in assembly.