Automatic Transmission Servicing Dodge Pickup R1500

APPLICATION

TRANSMISSION APPLICATION

Transmission identification numbers are stamped on left side of transmission case, just above the oil pan gasket surface. (Scheme 1)or (Scheme 2). Identification numbers may be required when ordering replacement components. Note that transmission components may not be interchangeable and identification number is required to ensure proper component application.

Scheme 1

Scheme 2

Check transmission fluid level every month. Under normal or severe service conditions, change transmission fluid and filter at specified interval. See TRANSMISSION SERVICE INTERVALS table. Severe service conditions are conditions such as long periods of engine idling, trailer towing, extreme temperatures, off-highway operation, snow removal, or operating in dusty conditions.

TRANSMISSION SERVICE INTERVALS

Transfer Case

Under normal or severe service conditions, change transfer case fluid at 30,000-mile or 24-month intervals.

1. Drive vehicle until engine and transmission are at normal operating temperature. Park vehicle on level surface. Apply parking brake.
2. With engine idling, shift transmission through all gear ranges, ending in Neutral. Check fluid level. Fluid level should be between MIN and MAX area on dipstick with transmission fluid temperature at 180°F (82°C). (Scheme 3) Transmission fluid temperature can be checked on models equipped with 4-speed transmissions using scan tool. Follow scan tool manufacturer's instructions. Add appropriate type of fluid as necessary. See «RECOMMENDED FLUID»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing__recommended-fluid). DO NOT overfill.

Scheme 3

Remove fill plug. Check fluid level. If fluid is not level with bottom of fill hole, add appropriate fluid. See RECOMMENDED FLUID .

RECOMMENDED FLUID

Manufacturer recommends Mopar® ATF+4, Type 9602 fluid.

Mopar® ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.

Manufacturer recommends Mopar® ATF+4, Type 9602 fluid.

Note. Transmission and torque converter capacities are approximate. Always determine fluid level with dipstick. See TRANSMISSION FLUID CAPACITIES table.

TRANSMISSION FLUID CAPACITIES

TRANSFER CASE FLUID CAPACITIES

1. Remove drain plug (if applicable) and drain fluid into appropriate receptacle. Loosen oil pan bolts. Tap pan to break loose, and allow fluid to drain. Remove oil pan and filter.
2. Install new filter on bottom of valve body. Tighten filter retaining screws to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications) . Install new "O" ring on fluid pickup pipe, if necessary. Clean oil pan, and install using new gasket. Tighten drain plug (if applicable).
3. Fill transmission with appropriate fluid. See «RECOMMENDED FLUID»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing__recommended-fluid) . Ensure vehicle is parked on level surface. Apply parking brake. Start engine and allow it to idle for a few minutes. Move gearshift lever through all gear ranges.
4. Return gearshift lever to "NEUTRAL". Add fluid up to MIN mark on dipstick. Recheck fluid level when transmission reaches normal operating temperature. Fluid should be between MIN and MAX marks on dipstick. Do not overfill transmission.

Remove drain plug from transfer case. Remove fill plug for easier draining. With fluid fully drained, reinstall drain plug. Fill transfer case with appropriate fluid. See RECOMMENDED FLUID . Install fill plug. Tighten drain and fill plugs to specification. See TORQUE SPECIFICATIONS .

OIL COOLER FLUSHING

Note. Manufacturer recommends Cooler Flusher (6906) for flushing oil cooler. Use only petroleum-based flushing solvents. Do not use solvents containing acids, water, gasoline or any other corrosive liquids.

1. Note oil cooler supply and return lines. Remove cover plate filler plug on cooler flusher. Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
2. Reinstall filler plug. Ensure pump power switch is in OFF position. Connect Red alligator clip to battery positive, and Black alligator clip to chassis ground. Disconnect oil cooler lines at transmission. NOTE: Always reverse flush when flushing oil cooler and lines. Converter drainback valve must be removed and an appropriate replacement hose (supplied with Cooler Flusher 6906) installed to bridge space between transmission cooler line and cooler fitting. Failure to remove drainback valve will prevent reverse flushing.
3. Connect Blue pressure line to outlet oil cooler line. Connect Clear return line to inlet oil cooler line. Turn pump on and flush oil cooler and lines for 3 minutes.
4. Monitor pressure reading and Clear return line. Check equipment manufacturer's instructions for pressure specifications. If solvent flow is intermittent or exceeds specified pressure, replace oil cooler(s).
5. Turn pump off. Disconnect Clear suction line from reservoir at cover plate. Turn pump on for 30 seconds to purge flushing solution from oil cooler lines. Turn pump off.
6. Place Clear suction line into a one quart container filled with ATF. Turn pump on until all fluid is removed from container. This removes remaining flushing solvent from oil cooler lines. Turn pump off.
7. Disconnect alligator clips from battery and ground. Remove flushing adapters from oil cooler lines. Reconnect oil cooler lines. Fill transmission to proper fluid level with ATF. See «CHECKING FLUID LEVEL»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing) under LUBRICATION.

OIL COOLER FLOW CHECK

1. With transmission filled to proper fluid level, disconnect oil cooler return line from transmission. Place container under oil cooler return line.
2. Add one extra quart of ATF to transmission. Apply parking brake. Start engine and allow it to idle. Place transmission in Neutral. Check fluid flow from oil cooler return line.
3. If fluid flow is intermittent or takes more than 20 seconds to obtain one quart, replace radiator or external oil cooler. Reconnect oil cooler return line. Fill transmission to proper fluid level with ATF. See «CHECKING FLUID LEVEL»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing) .

ON-VEHICLE REPAIRS

Note. Various components may be serviced without transaxle/transmission removal. For servicing of those components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional information on testing electrical components, see appropriate DIAGNOSIS article.

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.

1. Shift transmission into PARK.
2. Release cable adjuster lock tab (underneath the steering column) to unlock cable. (Scheme 4)
3. Raise vehicle.
4. Disengage the cable eyelet from the transmission 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 upward until it snaps into place.
10. Check engine starting. Engine should start only in "PARK" and "NEUTRAL".

Scheme 4

Control Pressure Adjustments

There are two control pressure adjustments on the valve body: Line Pressure and Throttle 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. Distance should be 1-5/16" (33.4 mm). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. (Scheme 5)

The 1-5/16" (33.4 mm) 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 9 kPa (1-2/3 psi). Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure.

Scheme 5

Throttle Pressure Adjustment

Insert Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem. (Scheme 6)

Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle 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.

The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment.

Scheme 6

REMOVAL & INSTALLATION

Removal

1. Shift transmission into "PARK".
2. Raise vehicle.
3. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket. (Scheme 7)or (Scheme 8).
4. Lower the vehicle.
5. Remove the dash panel insulation pad as necessary to access to the gearshift cable grommet. (Scheme 9)
6. Remove grommet from the dash panel.
7. Remove any steering column trim necessary to access to the gearshift cable and BTSI mechanism.
8. Disconnect the BTSI wiring connector.
9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. (Scheme 10)
10. Remove gearshift cable from vehicle.

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Installation

1. Route the transmission end of the gearshift cable through the opening in the dash panel. (Scheme 9)
2. Seat the cable grommet into the dash panel opening.
3. Snap the cable into the steering column bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. (Scheme 10)
4. Raise the vehicle.
5. Place the transmission manual shift lever in the "PARK" detent position and rotate prop shaft to ensure transmission is in "PARK".
6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping 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 mechanism as necessary. See «ADJUSTMENTS»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing__adjustments).

1. Raise vehicle.
2. Place a suitable fluid catch pan under the transmission.
3. Remove the wiring connector from the input speed sensor. (Scheme 11)
4. Remove the bolt holding the input speed sensor to the transmission case.
5. Remove the input speed sensor from the transmission case.

Scheme 11

1. Install the input speed sensor into the transmission case.
2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 105 INCH Lbs. (12 N.m).
3. Install the wiring connector onto the input speed sensor.
4. Verify the transmission fluid level. Add fluid as necessary.
5. Lower vehicle.

1. Raise vehicle.
2. Place a suitable fluid catch pan under the transmission.
3. Remove the wiring connector from the output speed sensor. (Scheme 12)
4. Remove the bolt holding the output speed sensor to the transmission case.
5. Remove the output speed sensor from the transmission case.

Scheme 12

1. Install the output speed sensor into the transmission case.
2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 105 INCH Lbs. (12 N.m).
3. Install the wiring connector onto the output speed sensor.
4. Verify the transmission fluid level. Add fluid as necessary.
5. Lower vehicle.

1. Raise vehicle and position drain pan under the transmission range sensor (TRS).
2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent.
3. Disengage the wiring connector from the TRS.
4. Remove the two screws holding the TRS to the TRS mounting bracket.
5. Remove the TRS from the TRS mounting bracket by pulling it straight out of the bracket. (Scheme 13)
6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581. (Scheme 14)
7. Remove the TRS mounting bracket from the transmission case. (Scheme 15)

Scheme 13

Scheme 14

Scheme 15

1. Move the transmission manual shaft lever to the manual LOW position.
2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581, tighten the mounting bracket to 25 ft. lbs. (34 N.m). (Scheme 14)
3. Install the TRS into the mounting bracket with the wiring connector facing the front of the transmission. (Scheme 13)
4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 45 INCH Lbs. (5 N.m).
5. Verify proper sensor operation. See 1 - 4. (Scheme 16)
6. Move the transmission manual shaft lever to the PARK position.
7. Connect TRS wiring connector to the TRS and lower vehicle.
8. Refill the transmission fluid to the correct level. See «RECOMMENDED FLUID»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing__recommended-fluid).

Scheme 16

1. Shift transmission into "NEUTRAL".
2. Raise vehicle.
3. Remove gearshift and throttle levers from shaft of valve body manual lever.
4. Disconnect wires at solenoid case connector. (Scheme 17)
5. Position drain pan under transmission oil pan.
6. Remove transmission oil pan and gasket.
7. Remove fluid filter from valve body.
8. Remove bolts attaching valve body to transmission case.
9. Lower valve body enough to remove accumulator piston and springs.
10. Work manual lever shaft and electrical connector out of transmission case.
11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. (Scheme 18)

Scheme 17

Scheme 18

1. Check condition of O-ring seals on valve body harness connector. Replace seals on connector body if cut or worn. (Scheme 19)
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. (Scheme 20)
3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. (Scheme 21)
4. Place valve body manual lever in low so ball on park lock rod will be easier to install in sprag.
5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case.
6. Lubricate seal rings on valve body harness connector with petroleum jelly.
7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement.
8. Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place.
9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case.
10. Then seat valve body in case and install one or two bolts to hold valve body in place.
11. Tighten valve body bolts alternately and evenly to 100 INCH Lbs. (11 N.m).
12. Install new fluid filter on valve body. Tighten filter screws to 35 INCH Lbs. (4 N.m).
13. Install throttle and gearshift levers on valve body manual lever shaft.
14. Connect solenoid case connector wires.
15. Install oil pan and new gasket. Tighten pan bolts to 105 INCH Lbs. (12 N.m) torque.
16. Lower vehicle and fill transmission with Mopar® ATF +4, type 9602 fluid.
17. Check and adjust gearshift and throttle valve cables, if necessary. See «ADJUSTMENTS»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing__adjustments).

Scheme 19

Scheme 20

Scheme 21

Removal (45RFE & 545RFE)

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 from valve body. (Scheme 22)
7. Remove bolts attaching valve body to transmission case. (Scheme 23)
8. Lower the valve body and work the electrical connector out of transmission case.
9. Separate the valve body from the transmission.

Scheme 22

Scheme 23

1. Check condition of seals on valve body and the solenoid and pressure switch assembly. Replace seals if cut or worn.
2. Place TRS selector plate in the PARK position.
3. Place the transmission in the PARK position.
4. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly.
5. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever.
6. Seat valve body in case and install one or two bolts to hold valve body in place.
7. Tighten valve body bolts alternately and evenly to 105 INCH Lbs. (12 N.m).
8. 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.
9. Place replacement filter in position on valve body and into the oil pump.
10. Install screw to hold filter to valve body. Tighten screw to 35 INCH Lbs. (4 N.m).
11. Connect the solenoid and pressure switch assembly connector.
12. Install oil pan. Tighten pan bolts to 105 INCH Lbs. (12 N.m).
13. Lower vehicle and fill transmission with Mopar® ATF +4, type 9602, fluid.
14. Check and adjust gearshift cable, if necessary. See «ADJUSTMENTS»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#automatic-transmission-servicing__adjustments) .

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• AIR BAG DEACTIVATION PROCEDURES
• TRANSMISSION SERVICE INTERVALS
• RECOMMENDED FLUID
• TORQUE SPECIFICATIONS
• ADJUSTMENTS
• REMOVAL & INSTALLATION