545RFE Automatic Transmission - Service Information: Specifications RAM Pickup 2500

SPECIFICATIONS

GENERAL

GEAR RATIOS

TORQUE SPECIFICATIONS

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1. Disconnect the negative battery cable.
2. Raise and support the vehicle
3. Remove any necessary skid plates. Refer to «PLATE, Skid, Front, Removal»(ref-457829-S37099224772012030200000) and «PLATE, Skid, Transfer Case, Removal»(ref-457829-S06628527422012030200000).
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) structural dust cover (2). 1 - TRANSMISSION 2 - OUTPUT SPEED SENSOR
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 converter 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). 1 - TRANSMISSION 2 - INPUT SPEED SENSOR
13. Disengage the input speed sensor connector from the input speed sensor (2). 1 - TRANSMISSION 2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
14. Disengage the transmission solenoid/TRS assembly connector from the transmission solenoid/TRS assembly (2). (Scheme 22) 1 - TRANSMISSION 2 - LINE PRESSURE SENSOR
15. Disengage the line pressure sensor connector from the line pressure sensor (2). 1 - GEARSHIFT CABLE 2 - RFE TRANSMISSION 3 - MANUAL LEVER
16. Disconnect gearshift cable (1) from transmission manual valve lever (3). 1 - ENGINE 2 - TRANSMISSION
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. If equipped, remove transfer case.
22. Disconnect transmission fluid cooler lines at transmission fittings and clips and position aside. NOTE: When disconnecting the transmission oil cooler lines, it is necessary to replace the line clip that is located on the oil pan stud. The retention force of the clip is severely degraded upon removal.
23. Remove all remaining converter housing bolts.
24. Remove the transmission dipstick tube.
25. Carefully work transmission and torque converter assembly rearward off engine block dowels.
26. Hold torque converter in place during transmission removal.
27. Lower transmission (2) and remove assembly from under the vehicle.
28. To remove torque converter, carefully slide torque converter out of the transmission.

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1. Drain fluid from transmission.
2. Clean exterior of transmission with suitable solvent or pressure washer.
3. Remove the torque converter from the transmission.
4. Remove the manual shift lever (1) from the transmission. (Scheme 27) 1 - OUTPUT SPEED SENSOR 2 - LINE PRESSURE SENSOR 3 - INPUT SPEED SENSOR
5. Remove the input (3), output (1), and line pressure sensors (2) from the transmission case. (Scheme 28)
6. Inspect the ends of the sensors for debris, which may indicate the nature of the transmission failure. 1 - TOOL 8257
7. Install Support Stand (special tool #8257, Support, Transmission) (1) onto the transmission case. (Scheme 29) 1 - TOOL 8266A 2 - TOOL C-3339A
8. Using Adapter (special tool #8266-1, Spline Tool, RFE Input) from End-Play Tool Set (special tool #8266B, End Play Socket Set) (1) and Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (2), measure and record the input shaft end-play. (Scheme 30) NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft is pulled outward is the movement of the input shaft in the 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. 1 - TOOL 10065 2 - TOOL 8266-20 3 - TOOL C-3339A
9. Remove the bolts holding the transmission extension/adapter housing to the transmission case.
10. Remove the extension/adapter housing from the transmission case.
11. Using Alignment Plate (special tool #8261, Plate, Alignment) (1), Adapter (special tool #8266-17, Spline Tool, RFE Output) from End-Play Tool Set (special tool #8266B, End Play Socket Set) (2) and Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (3), measure and record the output shaft end-play. (Scheme 31) 1 - PRIMARY OIL FILTER 2 - COOLER RETURN FILTER 3 - VALVE BODY
12. Remove the bolts holding the transmission oil pan to the transmission case.
13. Remove the transmission oil pan from the transmission case.
14. Remove the primary oil filter (1) and the oil cooler return filter (2). 1 - VALVE BODY TO CASE BOLT (6)
15. Remove the bolts (1) holding the valve body to the transmission case. (Scheme 33)
16. Remove the valve body from the transmission case. 1 - Front Cover 2 - Front Cover O-Ring 3 - Snap Ring 4 - Front Cover Seal
17. Remove the outer snap-ring (3) securing the transmission front cover (1) into the transmission case. (Scheme 34)
18. Reaching through a case opening in the valve body area with a long blunted tool, remove the transmission front cover (1) from the transmission case. (Scheme 34) 1 - OIL PUMP TO CASE BOLT (6) 2 - OIL PUMP
19. Remove the bolts (1) holding the oil pump into the transmission case. (Scheme 35)
20. Remove the oil pump (2). Hold inward on the input shaft to prevent pulling the input clutch assembly with the oil pump. (Scheme 35) CAUTION: If the input shaft is not held during oil pump removal, the input clutch assembly will attempt to move forward with the oil pump and the numbers 2, 3, or 4 bearings inside the input clutch assembly may become dislodged. 1 - THRUST BEARING NUMBER 5 2 - THRUST PLATE (SELECT) 3 - INPUT CLUTCH ASSEMBLY 4 - THRUST BEARING NUMBER 1
21. Remove the number 1 thrust bearing (4) from the input clutch assembly. (Scheme 36)
22. Remove the input clutch assembly (3) from the transmission case. (Scheme 36)
23. Remove the number 5 thrust bearing (1) and selective thrust plate (2) from the input clutch assembly (3), or the 4C clutch retainer/bulkhead. (Scheme 36) 1 - SNAP-RING 2 - 4C CLUTCH RETAINER/BULKHEAD
24. Remove the 4C clutch retainer/bulkhead tapered snap-ring (1) from the transmission case. (Scheme 37)
25. Remove the 4C clutch retainer/bulkhead (2) from the transmission case. (Scheme 37) 1 - SNAP-RING 2 - PLATE 3 - DISC 4 - REACTION PLATE
26. Remove the front 2C clutch pack snap-ring (1) from the transmission case. (Scheme 38)
27. Remove the 2C clutch pack (2, 3, 4) from the transmission case. (Scheme 38) 1 - THRUST BEARING NUMBER 8 5 - THRUST BEARING NUMBER 7 2 - THRUST BEARING NUMBER 9 6 - THRUST PLATE (SELECT) 3 - REACTION PLANETARY CARRIER 7 - THRUST BEARING NUMBER 6 4 - REACTION SUN GEAR 8 - REACTION ANNULUS
28. Remove the rear selective thrust plate (6) and number 6 thrust bearing (7) from the reaction annulus (8). (Scheme 39)
29. Remove the reaction annulus (8) from the reaction planetary carrier (3). (Scheme 39)
30. Remove the number 7 thrust bearing (5). (Scheme 39)
31. Remove the reaction sun gear (4). (Scheme 39)
32. Remove the number 8 thrust bearing (1) from the reaction planetary carrier (3). (Scheme 39)
33. Remove the reaction planetary carrier (3). (Scheme 39) Note that this planetary gear set has three pinion gears.
34. Remove the number 9 thrust bearing (2) from the reverse planetary gear set. (Scheme 39) 1 - SNAP-RING
35. Remove the snap-ring (1) holding the park sprag gear onto the output shaft. (Scheme 40) 1 - PARK SPRAG GEAR
36. Remove the park sprag gear (1) from the output shaft. (Scheme 41) 1 - INPUT/REVERSE PLANETARY ASSEMBLY 2 - BEARING NUMBER 9 3 - BEARING NUMBER 12
37. Remove the input/reverse planetary assembly (1). (Scheme 42)
38. Remove the number 12 thrust bearing (3) from the input/reverse planetary assembly (1). (Scheme 42) 1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY 2 - SNAP-RING
39. Remove the snap-ring (2) holding the low/reverse clutch retainer (1) into the transmission case. (Scheme 43)
40. Remove the low/reverse clutch retainer (1) from the transmission case. (Scheme 43) 1 - GUIDE 2 - SNAP-RING 3 - SHAFT 4 - SPRING 5 - PARK PAWL 6 - MANUAL SHAFT/LEVER 7 - PARK ROD
41. Remove the park rod (7) and e-clip. (Scheme 44)
42. Remove the park rod guide snap-ring (2). (Scheme 44)
43. Remove the park rod guide (1). (Scheme 44)
44. Remove the park pawl pivot shaft (3), park pawl (5), and spring (4). (Scheme 44)
45. Remove the manual selector shaft (6). (Scheme 44)
46. Remove the manual selector shaft seal.
47. Remove the dipstick tube seal.

TORQUE CONVERTER LIMIT VALVE

The torque converter limit valve serves to limit the available line pressure to the torque converter clutch.

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1. Remove the bolts holding the reaction shaft support (4) to the oil pump.
2. Remove the reaction shaft support (4) from the oil pump.
3. Remove all bolts holding the oil pump halves together.
4. Using suitable prying tools, separate the oil pump sections by inserting the tools in the supplied areas and prying the halves apart. NOTE: The oil pump halves are aligned to each other through the use of two dowels. Be sure to pry upward evenly to prevent damage to the oil pump components. 1 - SEPARATOR PLATE 5 - DOWEL (2) 2 - DRIVEN GEAR (2) 6 - DRIVE GEAR 3 - FLAPPER VALVE 7 - SCREW 4 - PUMP HOUSING
5. Remove the screws (7) holding the separator plate (1) onto the oil pump housing (4).
6. Remove the separator plate (1) from the oil pump housing (4).
7. Mark all gears for location. The gears are select fit and if the oil pump is to be reused, the gears must be returned to their original locations.
8. Remove the oil pump flapper valve (3) from its pocket in the pump housing.
9. Remove the oil pump gears (2, 6) from the oil pump housing (4). 1 - RETAINER 2 - T/C SWITCH VALVE 3 - OIL PUMP VALVE BODY
10. Remove the oil pump valve retainers (1) and associated valve (2) and spring one at a time. Mark the combination of components as a group and tag them as to the location from which they were removed. 1 - T/C REGULATOR VALVE 2 - T/C LIMIT VALVE 3 - MAIN REGULATOR VALVE 4 - OIL PUMP VALVE BODY
11. Remove the T/C regulator valve (1), T/C limit valve (2), and main regulator valve (3).

TORQUE CONVERTER CLUTCH (TCC)

In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission.

The clutch can be engaged in second, third, fourth, and fifth (if applicable) gear ranges depending on overdrive control switch position. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift to fourth gear. If the control switch is in the OFF position, the clutch will engage after the shift to third gear.

The TCM controls the torque converter clutch via the L/R-CC Solenoid. There are four TCC operational modes

1. No EMCC
2. Partial EMCC
3. Full EMCC
4. Gradual-to-no EMCC