Home ReviewsRefund
Home/Dodge/Pickup R3500/Dodge Pickup R3500 (1996-2010)/Repair manual/Automatic Trans/Automatic Transmission Servicing: Removal & Installation
Contents Wiring diagrams Section: Automatic Trans All sections

Automatic Transmission Servicing: Removal & Installation Dodge Pickup R3500

Automatic Trans 17 illustrations ~1378 words

REMOVAL & INSTALLATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES in AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

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 32)or (Scheme 33).
  4. Lower the vehicle.
  5. Remove the dash panel insulation pad as necessary to access to the gearshift cable grommet. (Scheme 34)
  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 35)
  10. Remove gearshift cable from vehicle.

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35

Installation

  1. Route the transmission end of the gearshift cable through the opening in the dash panel. (Scheme 34)
  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 35)
  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.
  1. Raise vehicle.
  2. Place a suitable fluid catch pan under the transmission.
  3. Remove the wiring connector from the input speed sensor. (Scheme 36)
  4. Remove the bolt holding the input speed sensor to the transmission case.
  5. Remove the input speed sensor from the transmission case.

Scheme 36

Scheme 36
Scheme 36
  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 37)
  4. Remove the bolt holding the output speed sensor to the transmission case.
  5. Remove the output speed sensor from the transmission case.

Scheme 37

Scheme 37
Scheme 37
  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 38)
  6. If necessary loosen the TRS mounting bracket in the transmission case using Adapter 8581. (Scheme 39)
  7. If necessary remove the TRS mounting bracket from the transmission case. (Scheme 40)

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40
  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 39)
  3. Install the TRS into the mounting bracket with the wiring connector facing the front of the transmission. (Scheme 38)
  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. (Scheme 41)
  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.

Scheme 41

Scheme 41
Scheme 41
  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 42)
  5. Remove the transmission range sensor. See «TRANSMISSION RANGE SENSOR»(ref-170037-S20968875932004122800000).
  6. Position drain pan under transmission oil pan.
  7. Remove transmission oil pan and gasket.
  8. Remove fluid filter from valve body.
  9. Remove bolts attaching valve body to transmission case.
  10. Lower valve body enough to remove accumulator piston and springs.
  11. Work manual lever shaft and electrical connector out of transmission case.
  12. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. (Scheme 43)

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43
  1. Check condition of O-ring seals on valve body harness connector. Replace seals on connector body if cut or worn. (Scheme 44)
  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 45)
  3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. (Scheme 46)
  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. Install the transmission range sensor. See «TRANSMISSION RANGE SENSOR»(ref-170037-S20968875932004122800000).
  15. Connect solenoid case connector wires.
  16. Install oil pan and new gasket. Tighten pan bolts to 105 INCH Lbs. (12 N.m ) torque. Install oil pan and new gasket.
  17. Lower vehicle and fill transmission with Mopar® ATF +4, type 9602 fluid.
  18. Check and adjust gearshift and throttle valve cables, if necessary. See «ADJUSTMENTS»(ref-170037-S13892477212004122800000).

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

Removal (45RFE)

  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 47)
  7. Remove bolts attaching valve body to transmission case. (Scheme 48)
  8. Lower the valve body and work the electrical connector out of transmission case.
  9. Separate the valve body from the transmission.

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Installation (45RFE)

  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»(ref-170037-S13892477212004122800000) .

More articles — Automatic Transmission Servicing