68RFE Automatic Transmission - Service Information: Removal & Installation RAM Pickup 2500

REMOVAL

Note. If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. Refer to MODULE, Transmission Control , Standard Procedure .

Scheme 213

Scheme 214

1. Remove the valve body from the transmission. 1 - SOLENOID PACK BOLTS (15)
2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body.
3. Separate the transmission solenoid/TRS assembly from the valve body.

Scheme 215

1. Place TRS selector plate in the PARK position.
2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate
3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body.
4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 N.m (50 in. lbs.).
5. Tighten the remainder of the solenoid assembly screws to 6 N.m (50 in. lbs.).
6. Install the valve body into the transmission.

1. Remove the bolts holding the transmission oil pan to the transmission case.
2. Remove the transmission oil pan from the transmission case.
3. Remove the snap ring (3) from the transmission case.
4. 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.

INSTALLATION

Note. To avoid contamination and garter spring dislodgment, do not handle the front cover seal (4) when positioning the front cover into the transmission case.

Scheme 216

1. Position a new front cover (1) into the transmission case. 1 - Front Cover installation Tool 9955
2. Using the front cover installation tool (special tool #9955, Installer, Front Cover) (1) and a dead-blow mallet, install the front cover into transmission case. 1 - FRONT COVER 2 - O - RING 3 - SNAP RING 4 - FRONT COVER SEAL
3. Install the snap ring (3) into the transmission case.
4. Apply RTV silicone to the oil pan and install the transmission oil pan.
5. Tighten the bolts to 12 N.m (105 in. lbs.).

FLUID AND FILTER REPLACEMENT

For proper service intervals, refer to Maintenance Schedules , Description .

Scheme 217

1. Hoist and support vehicle on safety stands.
2. Place a large diameter shallow drain pan beneath the transmission pan.
3. Remove bolts holding front and sides of pan to transmission.
4. Loosen bolts holding rear of pan to transmission.
5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan.
6. Hold up pan and remove remaining bolts holding pan to transmission.
7. While holding pan level, lower pan away from transmission.
8. Pour remaining fluid in pan into drain pan. 1 - PRIMARY OIL FILTER 2 - COOLER RETURN FILTER 3 - COOLER RETURN FILTER BYPASS VALVE 4 - VALVE BODY
9. Remove the screw holding the primary oil filter (1) to valve body. see scheme 138
10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan.
11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused.
12. If replacing the cooler return filter (2), use Oil Filter Wrench (special tool #8321, Wrench, Oil Filter) to remove the filter from the transmission.
13. Dispose of used trans fluid and filter(s) properly.

1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer (special tool #6960, Tools, Trac-Lok Axle) or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.).
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. see scheme 139 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 9.5 N.m (84 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 12 N.m (105 in. lbs.) torque.
8. Lower vehicle and fill transmission with MOPAR® ATF +4.

1. On 4WD vehicles remove the transfer case from the transmission, on 2WD vehicles remove the propeller shaft.
2. Using a pry tool, remove the output shaft seal.

Note. On the 2WD models use Seal Installer (special tool #8154, Installer, Seal) with Handle (special tool #C-4171, Driver Handle, Universal).

Scheme 218

1. Clean the seal bore in the extension housing of any residue or particles remaining from the original seal.
2. Install new oil seal in the extension housing using Handle (special tool #C-4171, Driver Handle, Universal) (1) and Seal Installer (special tool #10020, Installer, Seal) (2).

1. Remove the rear drive shaft. Refer to SHAFT, Drive, Rear Light Duty , Removal or SHAFT, Drive, Rear Heavy Duty , Removal .
2. Using a seal removal tool, remove rear extension housing output shaft seal.

1. Clean the extension housing seal bore in the extension housing of any residue or particles remaining from the original seal. NOTE: The small weep hole in the dust boot of the seal should face downward when installed in the extension housing.
2. Install new oil seal in the extension housing (1) using (special tool #8896, Installer, Seal) (2) and (special tool #C-4171, Driver Handle, Universal) (3).
3. Install rear drive shaft. Refer to SHAFT, Drive, Rear Light Duty , Installation or SHAFT, Drive, Rear Heavy Duty , Installation .

1. Install the input speed sensor (3) into the transmission case. see scheme 197
2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 N.m (105 in. lbs.).
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 line pressure sensor (2). see scheme 200
4. Remove the bolt holding the line pressure sensor (2) to the transmission case.
5. Remove the line pressure sensor (2) from the transmission case.

1. Install the line pressure sensor (2) into the transmission case. see scheme 201
2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 N.m (105 in. lbs.).
3. Install the wiring connector onto the line pressure sensor (2).
4. Verify the transmission fluid level. Add fluid as necessary.
5. Lower vehicle.

1. Remove transmission and torque converter from vehicle. Refer to Removal .
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 800/1000 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.

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 25 mm (1in.) 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. Refer to Installation .
9. Fill the transmission with the recommended fluid.

Scheme 219

The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch and frictional clutches. The valve body contains the following components

1. Solenoid switch valve
2. Manual valve
3. Low/reverse shuttle valve
4. 5 Accumulators

Scheme 220

1. 5 check balls

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.

Scheme 221

Scheme 222

1. Shift transmission into PARK.
2. Raise vehicle.
3. Disconnect wires at the solenoid and pressure switch assembly 23 pin electrical 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 223

Scheme 224

Scheme 225

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. 1 - TRS SELECTOR PLATE 2 - DETENT SPRING 3 - CLUTCH PASSAGE SEALS
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. 1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR 2 - LOW/REVERSE SHUTTLE VALVE AND PLUG 7 - UNDERDRIVE ACCUMULATOR 3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR 4 - MANUAL VALVE 9 - 2C ACCUMULATOR 5 - SOLENOID SWITCH VALVE AND PLUGS
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 five 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. 1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR 2 - LOW/REVERSE SHUTTLE VALVE AND PLUG 7 - UNDERDRIVE ACCUMULATOR 3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR 4 - MANUAL VALVE 9 - 2C ACCUMULATOR 5 - SOLENOID SWITCH VALVE AND PLUGS
13. Remove the retainer securing the solenoid switch valve (5) from the valve body. Remove the solenoid switch valve and plugs (5), the manual valve (4) and low reverse shuttle valve and plug (2). Tag each valve and plug combination with location information to aid in assembly.

Scheme 226

Clean the valve housings, valves, plugs, springs, transfer plate and separator plate with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution.

Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only.

Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages.

Scheme 227

Note. Only the INNER accumulator seal ring actually seals the pressure in the bore. The outer seal ring only serves to guide the piston in the bore. Gouges which do not extend past the inner seal ring (and have no raised edges, which could damage the guide ring) are acceptable. The machined accumulator bores often have a tiger-striped appearance. This is NORMAL and does NOT require replacement, as long as the bores are smooth in the inner seal ring area.

Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure.

Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced.

Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore.

Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils.

Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores.

Valve body bores do not normally change dimensionally with use. If the valve body functioned correctly when new, it should continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling.

Inspect all the accumulator bores in the valve body as well as the accumulator piston seal rings, and replace if cut or damaged. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils.

Scheme 228

Inspect all the fluid seals on the valve body. see scheme 224 Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems.

Scheme 229

Scheme 230

Scheme 231

1. Lubricate valves, plugs and the housing valve bores with clean transmission fluid.
2. Install solenoid switch valve and plugs and plugs (5) and the retainer into the valve body.
3. Install the valve body check balls into their proper locations.
4. Position the separator and transfer plate onto the valve body.
5. Install the screws to hold the transfer plate to the valve body. Tighten the screws to 6 N.m (50 in. lbs.). 1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR 2 - LOW/REVERSE SHUTTLE VALVE AND PLUG 7 - UNDERDRIVE ACCUMULATOR 3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR 4 - MANUAL VALVE 9 - 2C ACCUMULATOR 5 - SOLENOID SWITCH VALVE AND PLUGS
6. Install the accumulator piston seal rings onto each accumulator piston.
7. Install the accumulator pistons (1, 6-9) and springs into the valve body in the location from which they were removed. Note that all accumulators except the overdrive have two springs. The overdrive accumulator piston (6) has only one spring.
8. Install the Low / Reverse shuttle valve, plug, and retainer (2) into the valve body housing.
9. Position the accumulator cover onto the valve body.
10. Install the screws to hold the accumulator cover onto the valve body. Tighten the screws to 7 N.m (60 in. lbs.).
11. Install the manual valve (4). 1 - TRS SELECTOR PLATE 2 - DETENT SPRING 3 - CLUTCH PASSAGE SEALS
12. Install the TRS selector plate (1) onto the valve body and the manual valve.
13. Position the detent spring (2) onto the valve body.
14. Install the screw to hold the detent spring (2) onto the valve body. Tighten the screw to 4.5 N.m (40 in. lbs.).
15. Install new clutch passage seals (3) onto the valve body, if necessary. 1 - SOLENOID PACK BOLTS (15)
16. Install the solenoid and pressure switch assembly onto the valve body.
17. Install the bolts (1) to hold the solenoid and pressure switch assembly onto the valve body. Tighten the bolts to 6 N.m (50 in. lbs.). Tighten the bolts adjacent to the arrows cast into the bottom of the transfer plate first.

Scheme 232

Scheme 233

1. Place TRS selector plate in the PARK position.
2. Place the transmission in the PARK position.
3. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly.
4. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever.
5. Seat valve body in case and install one or two bolts to hold valve body in place.
6. Tighten valve body bolts alternately and evenly to 12 N.m (105 in. lbs.) torque.
7. Operate the external manual shift lever and ensure that the TRS selector plate moves correctly into all gear range positions. 1 - PRIMARY OIL FILTER 2 - COOLER RETURN FILTER 3 - COOLER RETURN FILTER BYPASS VALVE 4 - VALVE BODY CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result.
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 (1) in position on valve body and into the oil pump.
10. Install screw to hold filter to valve body. Tighten screw to 4.5 N.m (40 in. lbs.) torque.
11. Connect the solenoid and pressure switch 23 pin electrical assembly connector.
12. Install oil pan using silicone gasket sealer. Tighten pan bolts to 12 N.m (105 in. lbs.) torque.
13. Lower vehicle and fill transmission with Mopar® ATF +4.
14. Check and adjust gearshift cable, if necessary.