545RFE Automatic Transmission - Service Information: Removal & Installation RAM Pickup 3500

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 85

1. Remove the valve body from the transmission. see scheme 103 Refer to VALVE BODY, Removal. 1 - SOLENOID PACK BOLTS (15)
2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. see scheme 104
3. Separate the transmission solenoid/TRS assembly from the valve body.

INSTALLATION

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. see scheme 105
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.

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.

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 86

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 124
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 125 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. Remove the transfer case from the transmission.
2. Using a screw mounted on a slide hammer, remove the adapter housing seal.

Scheme 87

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 (special tool #C-3860-A, Installer, Seal) (1). see scheme 173 A properly installed seal is flush to the face of the seal bore.
3. Install the transfer case onto the transmission.

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 #C-3972-A, 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. Raise vehicle.
2. Place a suitable fluid catch pan under the transmission.
3. Remove the wiring connector from the input speed sensor (3). see scheme 175
4. Remove the bolt holding the input speed sensor to the transmission case.
5. Remove the input speed sensor (3) from the transmission case.

1. Install the input speed sensor (3) into the transmission case. see scheme 176
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 output speed sensor (1). see scheme 177
4. Remove the bolt holding the output speed sensor (1) to the transmission case.
5. Remove the output speed sensor (1) from the transmission case.

1. Install the output speed sensor (1) into the transmission case. see scheme 178
2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 N.m (105 in. lbs.).
3. Install the wiring connector onto the output speed sensor (1).
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 179
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 180
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.
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.

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). see scheme 223 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.

Scheme 88

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 89

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. Refer to VALVE BODY , Disassembly .

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. 1 - VALVE BODY TO CASE BOLT (6)
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.

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. (Scheme 89)
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 12 N.m (105 in. lbs.) torque.
8. 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.
9. 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.
10. Place replacement filter (1) in position on valve body and into the oil pump. see scheme 243
11. Install screw to hold filter to valve body. Tighten screw to 4.5 N.m (40 in. lbs.) torque.
12. Connect the solenoid and pressure switch 23 pin electrical assembly connector.
13. Install oil pan using silicone gasket sealer. Tighten pan bolts to 12 N.m (105 in. lbs.) torque.
14. Lower vehicle and fill transmission with Mopar ® ATF +4.
15. Check and adjust gearshift cable, if necessary.