Dodge 46RE Transmission Service Workshop Shop Repair Manual

INTRODUCTION 46RE, 47RE, 48RE, No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. Copyright © ATSG 2011 1st Printing April, 2011 AUTOMATIC TRANSMISSION SERVICE GROUP 18635 S.W. 107 AVENUE CUTLER BAY, FLORIDA 33157 (305) 670-4161 1 DALE ENGLAND FIELD SERVICE CONSULTANT ED KRUSE TECHNICAL CONSULTANT WAYNE COLONNA PRESIDENT PETER LUBAN TECHNICAL CONSULTANT JIM DIAL TECHNICAL CONSULTANT GREGORY LIPNICK TECHNICAL CONSULTANT JON GLATSTEIN TECHNICAL CONSULTANT DAVID CHALKER TECHNICAL CONSULTANT GREG CATANZARO TECHNICAL CONSULTANT GERALD CAMPBELL TECHNICAL CONSULTANT We wish to thank Chrysler® Group for the information that has made this booklet possible. The 46RE, 47RE and 48RE family of transmissions by the Chrysler Group, are fitted behind a wide variety of engine sizes, including diesel, and across various vehicle lines. They are also available in 2WD and 4WD configurations. Beginning at the start of production for model year 2005, Dodge trucks equipped with the 5.9L diesel and 48RE transmission were equipped with an electronically controlled Transmission Throttle Valve Actuator (TTVA). This Actuator has replaced the previous Throttle Valve Cable and all associated linkage. A push-in Transmission Range Sensor was implemented in model year 2002 to replace the screw-in Park/Neutral switch. The 46RE, 47RE and 48RE transmissions are all four speed fully automatic units with an electronic governor. They are equipped with a lock-up clutch in the torque converter. First through third gear ranges are provided by the clutches, bands, low-roller clutch, and planetary gearsets in the transmission. Fourth gear is provided by the overdrive unit (rear section) that contains an overdrive clutch, OD/direct clutch, overrun roller clutch, and planetary gearset. These units contain a front (direct) clutch, rear (forward) clutch, and OD/direct clutch which serve as the input driving components. They also contain a kickdown (front) band, low/reverse (rear) band, overrun clutch, and the overdrive clutch which serve as the holding components.

INDEX DODGE, JEEP 46RE, 47RE, 48RE 2 Copyright © ATSG 2011 AUTOMATIC TRANSMISSION SERVICE GROUP 18635 S.W. 107 AVENUE CUTLER BAY, FLORIDA 33157 (305) 670-4161 3 5 6 6 7 10 14 17 18 19 20 26 28 33 34 36 40 42 57 63 69 73 79 85 98 115 122 124 125 125 130 134 142 144 GENERAL DESCRIPTION AND VEHICLE APPLICATION CHART .................................... INTERNAL COMPONENT LOCATIONS .................................................................................. COMPONENT APPLICATION CHART, ID TAG LOCATION ................................................ FLUID SPECIFICATIONS .......................................................................................................... EXTERNAL ELECTRONIC COMPONENTS ............................................................................ TRANSMISSION THROTTLE VALVE ACTUATOR WIRE SCHEMATIC ............................. CONTROL MODULE LOCATIONS ............................................................................................ ELECTRICAL CONNECTOR AND TERMINAL IDENTIFICATION ..................................... TRANSMISSION CONTROL RELAY INFORMATION ............................................................ TOW/HAUL-OVERDRIVE CANCEL SWITCH ......................................................................... VEHICLE WIRE SCHEMATICS ................................................................................................ DIAGNOSTIC TROUBLE CODES .............................................................................................. INTERNAL ELECTRONIC COMPONENTS ............................................................................. LINE PRESSURE SPECS AND PRESSURE TAP LOCATIONS .............................................. ELECTRONIC GOVERNOR INFORMATION .......................................................................... GOVERNOR SOLENOID AND SENSOR DIAGNOSIS ............................................................ CASE PASSAGE IDENTIFICATION ......................................................................................... TRANSMISSION DISASSEMBLY .............................................................................................. COMPONENT REBUILD TRANSMISSION CASE ASSEMBLY .................................................................................. OIL PUMP ASSEMBLY ........................................................................................................ FRONT (DIRECT) CLUTCH HOUSING ASSEMBLY ....................................................... REAR (FORWARD) CLUTCH HOUSING ASSEMBLY ..................................................... TRANSMISSION GEARTRAIN ASSEMBLY ...................................................................... OVERDRIVE UNIT ASSEMBLY ......................................................................................... OVERDRIVE ROLLER CLUTCH FREEWHEEL DIRECTION ....................................... CHECK BALL LOCATIONS ................................................................................................. VALVE BODY ASSEMBLY ................................................................................................... VALVE BODY ADJUSTMENTS ........................................................................................... TRANSMISSION ASSEMBLY ..................................................................................................... LOW ROLLER CLUTCH FREEWHEEL DIRECTION ............................................................ BAND ADJUSTMENTS ............................................................................................................... OVERDRIVE SELECTIVE MEASUREMENTS ........................................................................ THRUST WASHER AND THRUST BEARING LOCATIONS .................................................. TORQUE SPECIFICATIONS ......................................................................................................

GENERAL DESCRIPTION Figure 1 VEHICLE APPLICATION CHART VEHICLE YEAR ENGINE COUNTRY TRANSMISSION GRAND CHEROKEE DODGE, DURANGO DODGE, RAM PICK-UP DODGE, RAM PICK-UP DODGE, RAM PICK-UP DODGE, RAM PICK-UP DODGE, RAM PICK-UP DODGE, VAN/WAGON DODGE, DAKOTA 1998 1998-03 1995-02 1995-02 1995-02 2003-07 2003-07 1995-03 1998-00 4.7L (V8) 5.9L, (V8) 5.2L, 5.9L, (V8) 5.9L, (Diesel) 8.0L (V10) 5.9L (Diesel) 8.0L (V10) 5.9L, (V8) 5.2L (V8) USA, USA, USA, MEX, USA, MEX, USA, MEX, USA, MEX, USA, MEX, USA, CAN, MEX, 46RE 46RE 46RE 47RE 47RE 48RE 48RE 46RE 46RE 3 Copyright © 2011 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information The 46RE, 47RE and 48RE family of transmissions by the Chrysler Group are fitted behind a wide variety of engine sizes and across various vehicle lines, as shown in Figure 1. They are also available in 2WD and 4WD configurations, as shown in Figure 2. Notice also in Figure 2, at the start of production for model year 2005, Dodge trucks equipped with the 5.9L diesel and 48RE transmission, were equipped with an electronically controlled Transmission Throttle Valve Actuator (TTVA). This Actuator has replaced the previous Throttle Valve Cable and all associated linkage. The push-in Range Sensor was implemented in model year 2002. The 46RE, 47RE and 48RE transmissions are all four speed fully automatic units with an electronic governor. They are equipped with a lock-up clutch in the torque converter. First through third gear ranges are provided by the clutches, bands, low-roller clutch, and planetary gearsets in the transmission. Fourth gear is provided by the overdrive unit (rear section) that contains an overdrive clutch, OD/direct clutch, overrun roller clutch, and planetary gearset. Refer to Figure 3 for the internal component locations and identification. These units contain a front clutch, rear clutch, and OD/direct clutch which serve as the input driving components. They also contain a kickdown (front) band, low/reverse (rear) band, overrun clutch, and the overdrive clutch which all serve as the holding components. The driving and holding components combine to select the necessary planetary gear components in the front, rear, or overdrive planetary gearset and transfer the engine power from the input shaft through to the output shaft. Refer to Figure 4 for the component application chart for which component is applied for each gear. First, second and third gear shifts are controlled by an electronic governor solenoid, that is mounted on the valve body assembly. The shift into fourth gear and torque converter clutch are controlled by individual seperate solenoids that are also mounted on the valve body assembly. The valve body is mounted on the lower side of the transmission and contains the valves necessary for pressure regulation, fluid flow control and clutch or band application. The valve body assembly has received several upgrades and changes over the years. The oil pump is mounted at the front of the transmission and is driven by the torque converter hub. The oil pump supplies the pressure necessary for clutch and/or band application and transmission lubrication.

PK5 54 8AA 97 58 28 23 2 4 1 9 2 2 3 3 8 8 6 6 K 9 F1 9 TP TK 7 5 2 4 8 2 4 8 K 8 2 A P 5 5 3 A 3 28 AA SIEMENS VDO SIEMENS VDO 0 0 6 6 4 4 1 1 PK52 4238 A 297 589 85 A 41 K 94 8 TP TK 7 F1 9 2 5 2 P 5 5 3A K2 4 8 A 8 28 3 A A Figure 2 4 Copyright © 2011 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 2WD Gas Version 4WD Diesel Version Some Models Equipped With Screw-In P/N Switch (1995-2001 Models) Some Models Equipped With Push-In Range Sensor (2002-Up All Models) Throttle Valve Acuator (2005-Up Diesel Models Only)

5 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Copyright © 2011 ATSG Figure 3 INTERNAL COMPONENT LOCATION AND IDENTIFICATION FRONT (INTERMEDIATE) BAND REAR (LOW/REVERSE) BAND LOW ROLLER CLUTCH FRONT (DIRECT) CLUTCH REAR (FORWARD) CLUTCH OVERDRIVE CLUTCH (Diesel) OVERDRIVE CLUTCH (Gasoline) OVERDRIVE ROLLER CLUTCH OUTPUT SPEED SENSOR OVERDRIVE/DIRECT CLUTCH

PK5 4 29 15 285 238AA 74 89 2 2 3 3 8 8 6 6 K 9 F1 TK 7 59 TP 2 4 8 2 4 K 8 2 8A P 5 5 3 A 3 28 A A COMPONENT APPLICATION CHART Gear Ratio 2.20 2.45 2.45 1.45 1.45 1.00 0.69 Front Clutch Front Band Rear Clutch Rear Band Low-Roller Clutch Overdrive Clutch OD/Direct Clutch OD Roller Clutch Reverse OD-1st Man-1st ON ON ON ON ON ON ON ON ON ON Hold Hold ON ON ON ON Hold Hold Hold Hold Hold ON ON ON ON ON ON OD-2nd Man-2nd OD-3rd OD-4th Note: The torque converter clutch may be applied in 3rd or 4th gears. The torque converter clutch may also be engaged in Manual 2nd gear position, if high transmission temperatures are detected by the TCM/PCM/ECM. Figure 4 Figure 4A Bar Code Label Located Here ID Numbers Also Etched Into Case Pan Rail Here IDENTIFICATION TAG LOCATION IDENTIFICATION TAG AND FLUID REQUIREMENTS Fluid Requirements "ATF+4" Copyright © 2011 ATSG TPKTK2974F1589 PK52854238AA 238 AA The Bar Code Label is located on the left hand side of the transmission case, as shown in Figure 4A. Transmission identification numbers are also etched into the left side of case pan rail just above the oil pan gasket, as shown in Figure 4A. Always refer to this information when ordering replacement parts. These units require "ATF+4" fluid, as shown in Figure 4A. 6 Copyright © 2011 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PK52854238AA 2974 1589 Part Number Build Date Serial Number { { {

7 Copyright © 2011 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information EXTERNAL ELECTRONIC COMPONENTS Output Speed Sensor (OSS) PK5 54 8AA 97 58 28 23 2 4 1 9 2 2 3 3 8 8 6 6 K 9 F1 9 TP TK2 7 58 4 2 4 8 K 8 2 A P 5 5 3 A 3 28 AA SIEMENS VDO SIEMENS VDO Throttle Valve Actuator 2005-Up Diesel Only Output Speed Sensor All Models 8-Way Case Connector All Models "Push-In" Range Sensor 2002-Up "Screw-In" Park/Neutral Switch 1995-2001 EXTERNAL ELECTRONIC COMPONENT LOCATIONS The Output Speed Sensor (OSS) is located in the overdrive case housing, as shown in Figure 5, and is positioned over the park gear. The OSS monitors rotating speed of the output shaft. The OSS is triggered by the external park lugs on the rear planetary ring gear to determine the exact transmission output shaft speed. The OSS signal, and other inputs, are used by the TCM/PCM/ECM to determine the required governor pressure for current conditions. This has a direct effect on which gear is chosen for the vehicle. The controller also uses this information to schedule torque converter lock-up. Should the OSS fail, the speed signal from the ABS control module is used as a back-up, and code P0720 will be stored in TCM/PCM/ECM memory. The OSS sensor and wire schematic for Gas and Diesel is shown in Figure 6. Figure 5 OUTPUT SPEED SENSOR (OSS) Special Note: The OSS is best checked using a scope under operating conditions. 1 28 2 25 1 44 2 45 Twisted Pair C2 Conn C2 Conn OSS SIG OSS GND OSS GND OSS SIG ECM 2004-UP (DIESEL) PCM 1996-03 (GAS & DIESEL) 1 2 Output Speed Sensor Harness Connector (Face View) 13 14 Figure 6 13 OUTPUT SHAFT SPEED SENSOR (ALL MODELS). 14 OUTPUT SPEED SENSOR "O" RING SEAL. Copyright © 2011 ATSG

8 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 6 THROTTLE VALVE ACTUATOR (2005-UP DIESEL ONLY). 7 THROTTLE VALVE ACTUATOR BOLTS (2 REQUIRED). 6 7 EXTERNAL ELECTRONIC COMPONENTS (CONT'D) Transmission Throttle Valve Acuator (TTVA) Figure 7 Beginning at the start of production for the 2005 model year, all Dodge trucks equipped with the 5.9L diesel engine and the 48RE transmission, received an electronically controlled Transmission Throttle Valve Actuator (TTVA), as shown in Figure 7, for improved shift control. The TTVA is mechanically connected to the throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft and retained with two mounting bolts, as shown in Figure 7. This required two added bosses to the transmission case. The TTVA has replaced the previous Throttle Valve Cable and all associated mechanical linkage, on diesel models only. The TTVA consists of an electronic DC motor, two potentiometers and a gear driven system that controls all functions of the throttle valve in the valve body. The position of the geartrain is monitored by the TTVA Position sensor which supplies an input to the Engine Control Module (ECM). The TTVA is controlled by the ECM thru the inputs of Accelerator Position Sensor 1 and 2. Refer to the charts in Figure 8 for observed voltage and percent of opening, from a working vehicle, of APP1 and APP2 to the voltages that control the TTVA and the TTVA position voltage feedback to the ECM. Refer to Figure 11 for wiring schematic of the accelerator pedal position sensor to assist you in the diagnosis process as necessary. Note: If the TTVA is removed or replaced, the ECM will have to relearn it's "0" position. The ignition will have to be turned on, with the engine off, for 30 seconds to accomplish "Auto Zero." With the addition of the TTVA a new wiring harness was required. Refer to Figure 10 for a partial wire schematic of the TTVA and its connectors. Refer to Figure 9 for a list of new Diagnostic Trouble Codes related to the TTVA. If a new case is required, it must be a 2005 or later case because of the added bosses to the case to accommodate the TTVA. Added Case Bosses PK 85 238 A 29 4 89 52 4 A 7 15 K T K297 F1 9 P T 4 58 85 38A PK52 42 A 8 23 A A SIEMENS VDO SIEMENS VDO Copyright © 2011 ATSG

9 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "OBSERVED" VOLTAGE AND PERCENTAGE CHARTS TTVA Position Sensor (Voltage) CLOSED THROTTLE TTVA POSITION SENSOR SIGNAL WIDE OPEN THROTTLE 3.78V .73V Note: TTVA motor control and TTVA position sensor are subject to change, and there are no adjustments. The ECM will re-calibrate its current "0" position when the ignition is turned on and the engine not running for 30 seconds. TTVA + (Voltage) CLOSED THROTTLE TTVA MOTOR VOLTAGE WIDE OPEN THROTTLE 2.0 -2.5V 0 -.70V Note: Using a DVOM set to DC volts, backprobe terminal number 8 at the ECM C1 60-way connector with the red probe and the black probe to a good ground (See Figure 10). Note: On 2005 diesel models only, using a DVOM set to DC volts, backprobe terminal number 35 at the ECM C1 60-way connector with the red probe and the black probe to a good ground (See Figure 10). Note: On 2006-Up diesel models only, using a DVOM set to DC volts, backprobe terminal number 27 at the ECM C2 50-way connector with the red probe and the black probe to a good ground (See Figure 10). Accelerator Pedal Position Sensor 1 (Percent) Accelerator Pedal Position Sensor 2 (Percent) Accelerator Pedal Position Sensor 1 (Voltage) Accelerator Pedal Position Sensor 2 (Voltage) CLOSED THROTTLE WIDE OPEN THROTTLE 2 % .45V 96 % 4.56V 3 % 97 % .24V 2.29V ACCELERATOR POSITION SENSOR Note: This test administered using a scanner. DTC TTVA Position Sensor Low (Electrical) TTVA Position Sensor High (Electrical) TTVA Acuator Stuck (Electrical/Mechanical) TTVA Position Mechanical Performance (Mechanical) TTVA Control Circuit (Electrical/Mechanical) P1749 P1750 P1753 P1754 P1755 TRANSMISSION THROTTLE VALVE ACTUATOR CODES DESCRIPTION TTVA Position Sensor Minimum Range Performance (Mechanical) P1751 Note: Some of the DTC's listed can cause the voltage to the TTVA to be shut off by the ECM, this will in turn cause the TTVA motor position to be in high TV mode. Figure 8 Figure 9 Copyright © 2011 ATSG Copyright © 2011 ATSG

TRANSMISSION THROTTLE VALVE ACTUATOR PARTIAL ELECTRICAL SCHEMATIC 1 2 6 5 3 4 2005 Diesel Models Only Connector Views For All Diesel (2004-Up) 2006-Up Diesel Models Only ECM - C2 50-Way Connector (Face View) ECM - C1 60-Way Connector (Face View) 10 20 30 40 50 60 1 11 21 31 41 51 Note: numbers are marked on connector 1 11 21 31 41 10 20 30 40 50 Note: numbers are marked on connector TTVA 6-Way Connector (Face View) Figure 10 35 1 20 5 6 24 23 2 8 3 4 5 VOLT SUPPLY 5 VOLT SPLY TTVA POSITION SENS SIG TTVA POSITION SENS SIG NOT USED TTVA MOTOR (+) TTVA MOTOR (+) TTVA MOTOR (-) TTVA MOTOR (-) SENSOR GND ENGINE CONTROL SYSTEM SENSOR GND Transmission Throttle Valve Acuator (TTVA) 2005 ECM Dk Blue/Dk Green Yellow/Pink Tan/Yellow Orange Tan/Orange Dk Blue/Dk Green Dk Blue/Dk Green C2 Conn Top Front Of Transmission C1 Conn TTVA Conn 27 1 20 5 6 24 23 2 8 3 4 5 VOLT SUPPLY 5 VOLT SPLY TTVA POSITION SENS SIG TTVA POSITION SENS SIG NOT USED TTVA MOTOR (+) TTVA MOTOR (+) TTVA MOTOR (-) TTVA MOTOR (-) SENSOR GND ENGINE CONTROL SYSTEM SENSOR GND Transmission Throttle Valve Acuator (TTVA) 2006-UP ECM Yellow/Pink Tan/Yellow Orange Tan/Orange Dk Blue/Dk Green Dk Blue/Dk Green Dk Blue/Dk Green Top Front Of Transmission C2 Conn C1 Conn TTVA Conn { { { 10 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Copyright © 2011 ATSG

Dodge 46RE Transmission Service Workshop Shop Repair Manual

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