Chrysler 48RE Manual Download | Manualshive

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(16) Install direct clutch spring (Fig. 157). Be sure

spring is properly seated on spring plate.

NOTE: The direct clutch in a 48RE transmission
uses 23 single-sided clutch discs.

(17) Assemble and install direct clutch pack on

hub as follows:

(a) Install direct clutch reaction plate on clutch

hub first. Note that one side of reaction plate is
counterbored. Be sure this side faces rearward.
Splines at rear of hub are raised slightly. Counter-
bore in plate fits over raised splines. Plate should
be flush with this end of hub (Fig. 158).

(b) Install first clutch disc with internal splines

friction side up, followed by a disc with external
lugs friction side up. Continue alternating internal
and external discs until all discs have been
installed.

Fig. 158 Correct Position Of Direct Clutch Reaction

Plate

1 -

REACTION PLATE COUNTERBORE

2 - DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF HUB)
3 - CLUTCH HUB

Fig. 157 Direct Clutch Spring Installation

1 - SPECIAL TOOL 6227-2
2 - DIRECT CLUTCH SPRING
3 - CLUTCH HUB
4 - PRESS PLATES

DR

AUTOMATIC TRANSMISSION - 48RE

21 - 229

OVERDRIVE UNIT (Continued)

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Summary of Contents for 48RE

Page 1: ... SHIFT INTERLOCK SYSTEM DESCRIPTION 196 OPERATION 196 DIAGNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK 196 ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK 196 ELECTRONIC GOVERNOR DESCRIPTION 197 OPERATION 198 REMOVAL 199 INSTALLATION 200 EXTENSION HOUSING SEAL REMOVAL 201 INSTALLATION 201 FLUID AND FILTER DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL 201 DIAGN...

Page 2: ...T MECHANISM DESCRIPTION 252 OPERATION 252 SOLENOID DESCRIPTION 252 OPERATION 252 SPEED SENSOR DESCRIPTION 253 OPERATION 253 THROTTLE VALVE CABLE DESCRIPTION 253 ADJUSTMENTS THROTTLE VALVE CABLE 254 TORQUE CONVERTER DESCRIPTION 255 OPERATION 259 REMOVAL 260 INSTALLATION 260 TORQUE CONVERTER DRAINBACK VALVE DESCRIPTION 261 OPERATION 261 STANDARD PROCEDURE TORQUE CONVERTER DRAINBACK VALVE 261 TOW HAU...

Page 3: ...lso contains the kickdown front and the low reverse rear bands which along with the over running clutch and overdrive clutch serve as the holding components The driving and holding compo nents combine to select the necessary planetary gear components in the front rear or overdrive planetary gear set transfer the engine power from the input shaft through to the output shaft The valve body is mounte...

Page 4: ...Fig 1 48RE Transmission DR AUTOMATIC TRANSMISSION 48RE 21 133 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 5: ...r under various conditions such as when the O D switch is OFF when the vehicle is cruising on a level surface after the vehicle has warmed up The torque converter clutch can also be engaged in the MANUAL SECOND gear position if high trans mission temperatures are sensed by the PCM The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM such as wh...

Page 6: ...ub and rear clutch retainer stops at the rear clutch retainer Therefore no power flow to the output shaft occurs because no clutches are applied The only mechanism in use at this time is the park ing sprag Fig 3 which locks the parking gear on the output shaft to the transmission case NEUTRAL POWERFLOW With the gear selector in the NEUTRAL position Fig 4 the power flow of the transmission is essen...

Page 7: ...transferred to the rear annulus gear which is splined to the output shaft The output shaft in turn rotates with the annulus gear in a counterclockwise direction giving a reverse gear out put The entire transmission of torque is applied to the rear planetary gearset only Although there is torque input to the front gearset through the sun gear no other member of the gearset is being held During the ...

Page 8: ...in a clockwise direction With the rear annulus gear stationary the rear planet rotation on the annulus gear causes the rear planet carrier to revolve in a counterclockwise direction The rear planet carrier is splined into the low reverse drum and the low reverse drum is splined to the inner race of the over running clutch With the over running clutch locked the planet car rier is held and the resu...

Page 9: ...ry the annulus rotation causes the front planets to rotate in a clockwise direction The front carrier is then also made to rotate in a clockwise direction but at a reduced speed This will transmit the torque to the output shaft which is directly connected to the front planet carrier The rear planetary annulus gear will also be turning because it is directly splined to the output shaft All power fl...

Page 10: ... trolled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens and closes a vent port in the 3 4 shift valve feed passage The overdrive solenoid and check ball are not ener gized in first second third or reverse gear The vent port remains open diverting line p...

Page 11: ...tch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission into gear and note following a If propeller shaft turns but wheels do not problem is with differential o...

Page 12: ...n fourth gear the overdrive clutch is slipping Simi larly if the direct clutch were to fail the transmis sion would lose both reverse gear and overrun braking in 2 position manual second gear If the transmission will not shift to fourth gear the control switch overdrive solenoid or related wiring may also be the problem cause This process of elimination can be used to identify a slipping unit and ...

Page 13: ... one detent rear ward from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure on gauge 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as lever is moved rearward Test Three Transmission In D Range Third Gear This test checks pressure regul...

Page 14: ... pressure at the overdrive clutch in fourth gear range Use 300 psi Test Gauge C 3293 SP for this test The test should be performed on the road or on a chassis dyno 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive clutch pres sure test port Then remove other gauge and reinstall test port plug 3 Lower vehicle 4 Turn OD switch on 5 Secure test gauge so it can be vi...

Page 15: ...the servo when air pressure is removed DIAGNOSIS AND TESTING CONVERTER HOUSING FLUID LEAK When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak condition actually exists 2 Determined the true source of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter ...

Page 16: ... 6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatext No 2 to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 9 Install transmission and converter housing dust shield 10 Lower vehicle DIAGNOSIS AND TESTING DIAGNOSIS CHARTS The diagnos...

Page 17: ...sh Incorrect 5 Check per Service Manual Correct as needed 6 Hydraulic Pressure Incorrect 6 Check pressure Remove overhaul or adjust valve body as needed 7 Band Mis adjusted 7 Adjust rear band 8 Valve Body Check Balls Missing 8 Inspect valve body for proper check ball installation 9 Axle Pinion Flange Loose 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if thre...

Page 18: ...ve transmission and repair as needed 10 Reaction Shaft Seal Rings Worn Broken 10 Remove transmission remove oil pump and replace seal rings 11 Rear Clutch Input Shaft Rear Clutch Seal Rings Damaged 11 Remove and disassemble transmission and repair as necessary 12 Regulator Valve Stuck 12 Clean 13 Cooler Plugged 13 Transfer case failure can plug cooler NO DRIVE RANGE REVERSE OK 1 Fluid Level Low 1 ...

Page 19: ...n Repair or replace failed components as needed 8 Park Sprag not Releasing Check Stall Speed Worn Damaged Stuck 8 Remove disassemble repair 9 Torque Converter Damage 9 Inspect and replace as required SHIFTS DELAYED OR ERRATIC SHIFTS ALSO HARSH AT TIMES 1 Fluid Level Low High 1 Correct fluid level and check for leaks if low 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutc...

Page 20: ...T REVERSE ONLY NO 1 2 OR 2 3 UPSHIFT 1 Governor Circuit Electrical Fault 1 Test using DRBT scan tool and repair as required 2 Valve Body Malfunction 2 Repair stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band Damaged Burned 3 Repair replace MOVES IN 2ND OR 3RD GEAR ABRUPTLY DOWNSHIFTS TO LOW 1 Valve Body Malfunction 1 Remove clean and inspect Look for stuck 1 2 valve or governor pl...

Page 21: ...nction 7 Check with DRBT scan tool and replace if required 8 Valve Body Malfunction 8 Repair sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve STUCK IN LOW GEAR WILL NOT UPSHIFT 1 Throttle Linkage Mis adjusted Stuck 1 Adjust linkage and repair linkage if worn or damaged Check for binding cable or missing return spring 2 Gearshift Linkage Mis adjusted 2 Adju...

Page 22: ...rmine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Mis a...

Page 23: ...ges in case 5 Servo Band or Linkage Malfunction 5 Air pressure check servo operation and repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 8 Converter Clutch Dragging 8 Check for plugged cooler Perform flow check Inspect pump for excessive side clearance Replace pum...

Page 24: ...URS IMMEDIATELY AFTER 2 3 SHIFT 1 Overdrive Solenoid Connector or Wiring Shorted 1 Test connector and wiring for loose connections shorts or ground and repair as needed 2 TPS Malfunction 2 Test TPS and replace as necessary Check with DRBT scan tool 3 PCM Malfunction 3 Test PCM with DRBT scan tool and replace controller if faulty 4 Overdrive Solenoid Malfunction 4 Replace solenoid 5 Valve Body Malf...

Page 25: ...gine no start 7 PCM Malfunction 7 Check with DRBT scan tool and replace if necessary 8 Overdrive Solenoid Shorted Open 8 Replace solenoid if shorted or open and repair loose or damaged wires DRBT scan tool 9 Solenoid Feed Orifice in Valve Body Blocked 9 Remove disassemble and clean valve body thoroughly Check feed orifice 10 Overdrive Clutch Failed 10 Disassemble overdrive and repair as needed 11 ...

Page 26: ... shaft 7 O D Check Valve Bleed Orifice Failure 7 Check for function secure orifice insert in O D piston retainer DELAYED 3 4 UPSHIFT SLOW TO ENGAGE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Throttle Valve Cable Mis adjusted 2 Adjust throttle valve cable 3 Overdrive Clutch Pack Worn Burnt 3 Remove unit and rebuild clutch pack 4 TPS Faulty 4 Test with DRBT scan tool and replace as necessar...

Page 27: ...pair 5 Valve Body Manual Lever Assembly Bent Worn Broken 5 Inspect lever assembly and replace if damaged NO REVERSE OR SLIPS IN REVERSE 1 Direct Clutch Pack front clutch Worn 1 Disassemble unit and rebuild clutch pack 2 Rear Band Mis adjusted 2 Adjust band 3 Front Clutch Malfunctioned Burned 3 Air pressure test clutch operation Remove and rebuild if necessary 4 Overdrive Thrust Bearing Failure 4 D...

Page 28: ...ks 10 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 11 Pump Seal Leaks Worn Damaged 11 Replace seal 12 Torque Converter Weld...

Page 29: ...CAL STARTING STARTER MOTOR REMOVAL 7 Disconnect and remove the crankshaft position sensor Refer to 14 FUEL SYSTEM FUEL INJEC TION CRANKSHAFT POSITION SENSOR REMOVAL Retain the sensor attaching bolts 8 If transmission is being removed for overhaul remove transmission oil pan drain fluid and reinstall pan 9 Remove torque converter access cover 10 Rotate crankshaft in clockwise direction until conver...

Page 30: ...out of transmission Retain fill tube seal On 4X4 models it will also be necessary to remove bolt attaching transfer case vent tube to converter hous ing Fig 16 23 Remove all converter housing bolts 24 Carefully work transmission and torque con verter assembly rearward off engine block dowels 25 Lower transmission and remove assembly from under the vehicle 26 To remove torque converter remove C cla...

Page 31: ... install Alignment Shaft 6227 2 into the over drive unit to prevent misalignment of the overdrive clutches during service of main transmission compo nents 5 Remove throttle and shift levers from valve body manual shaft and throttle lever shaft 6 Remove transmission oil pan and gasket 7 Remove filter from valve body Fig 18 Keep filter screws separate from other valve body screws Filter screws are l...

Page 32: ...n shaft support assembly as follows a Tighten front band adjusting screw until band is tight around front clutch retainer Fig 23 This will prevent retainer from coming out with pump and possibly damaging clutch or pump com ponents Fig 23 Tightening Front Band To Hold Front Clutch In Place 1 LOCK NUT 2 FRONT BAND ADJUSTER Fig 20 Valve Body Removal 1 GOVERNOR PRESSURE SENSOR 2 VALVE BODY 3 PARK ROD ...

Page 33: ...osition in case for assembly reference 16 Loosen front band adjusting screw until band is completely loose 17 Remove front band strut and anchor Fig 27 Fig 24 Oil Pump Removal Tools 1 PUMP HOUSING 2 SLIDE HAMMER TOOLS THREAD INTO PUMP HOUSING Fig 25 Oil Pump Removal 1 OIL PUMP AND REACTION SHAFT SUPPORT Fig 26 Oil Pump Gasket 1 OIL PUMP GASKET Fig 27 Front Band Linkage 1 LEVER 2 STRUT 3 ANCHOR 4 F...

Page 34: ...0 21 Remove intermediate shaft thrust washer Tri angular shaped washer will either be on shaft pilot hub or in rear clutch retainer Fig 31 Fig 29 Removing Front Rear Clutch Assemblies 1 FRONT AND REAR CLUTCH ASSEMBLIES Fig 30 Front Band Lever And Pin 1 BAND LEVER 2 USE PENCIL MAGNET TO REMOVE REACTION PIN Fig 31 Intermediate Shaft Thrust Washer 1 THRUST WASHER 2 INTERMEDIATE SHAFT PILOT HUB Fig 28...

Page 35: ...ust washer off piston retainer hub and out of rear band Fig 35 Fig 35 Low Reverse Drum And Thrust Washer 1 LOW REVERSE DRUM 2 SPOTFACE FOR WASHER 3 THRUST WASHER Fig 32 Intermediate Shaft Thrust Plate 1 SHAFT THRUST PLATE 2 INTERMEDIATE SHAFT PILOT HUB Fig 33 Intermediate Shaft And Planetary Geartrain 1 INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN ASSEMBLY Fig 34 Low Reverse Drum Snap Ring 1 LOW RE...

Page 36: ... Tool C 4470 or Compressor Tool C 3422 B Fig 38 Compress guide only enough to permit snap ring removal about 1 8 in 32 Remove servo piston snap ring Fig 38 Unseat one end of ring Then carefully work removal tool around back of ring until free of ring groove Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised Fig 38 Front Servo Retaining Snap Ring...

Page 37: ...ored bush ings contribute to low pressures clutch slip and accelerated wear of other components However do not replace bushings as a matter of course Replace bushings only when they are actually worn or scored The use of crocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges Sharp edges are vital ...

Page 38: ...Install rear servo spring and retainer in case bore Fig 41 Be sure spring is seated on piston 4 Compress rear servo piston with C clamp or Valve Spring Compressor C 3422 B and install servo piston snap ring Fig 42 5 Lubricate front servo piston components and servo bore in case with transmission fluid 6 Install front servo piston in bore Carefully run small suitable tool around piston ring to pres...

Page 39: ...iston retainer hub and into engage ment with overrunning clutch and race 4 Install thrust washer in low reverse drum spot face Fig 45 Use petroleum jelly to hold washer in place 5 Install snap ring that secures low reverse drum to piston retainer hub Fig 45 6 Insert the rear band pivot pin part way into the case 7 Install rear band adjusting lever and pivot pin Be sure lever and the single lug on ...

Page 40: ...onal cut ends of front seal rings are firmly seated against each other as shown Lubricate seal rings with petro leum jelly after checking them 5 Assemble front and rear clutches Fig 49 Align lugs on front clutch discs Mount front clutch on rear clutch Turn front clutch retainer back and forth until front clutch discs are fully seated on rear clutch splined hub Fig 46 Intermediate Shaft And Planeta...

Page 41: ...1 Turn clutch retainers back and forth until both clutches are seated 9 Position front band lever in case and over servo rod guide Then install front band lever pin in case and slide it through lever 10 Coat threads of front band pin access plug with sealer and install it in case Tighten plug to 17 N m 13 ft lbs torque Fig 50 Intermediate Shaft Thrust Washer 1 BE SURE WASHER GROOVES FACE OUT AS SH...

Page 42: ...53 3 Coat the reaction shaft thrust washer with petroleum jelly to hold it in place Then install washer over reaction shaft hub and seat it on pump Fig 54 CAUTION The thrust washer bore I D is cham fered on one side Make sure the chamfered side is installed so it faces the pump Fig 53 Oil Pump Gasket And Pilot Studs 1 OIL PUMP GASKET 2 PILOT STUDS C 3288 B Fig 54 Front Clutch Thrust Washer Install...

Page 43: ...E If end play is incorrect transmission is incorrectly assembled or reaction shaft thrust washer is incorrect The reaction shaft thrust washer is selective a Attach Adapter 8266 5 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266 5 to secure it to the input shaft d P...

Page 44: ... fiber contamination in the fluid replace the torque converter and reverse flush the cooler s and cooler lines Fluid contamination and transmis sion failure can result if not done 6 Move the transmission manual shaft lever to the manual LOW position 7 Install the TRS mounting bracket into the transmission case Using Adapter 8581 Fig 60 tighten the mounting bracket to 34 N m 300 in lbs 8 Install th...

Page 45: ...must be smooth to avoid damaging pump seal at installation 2 Lubricate pocket in the rear oil pump seal lip with transmission fluid 3 Lubricate converter pilot hub of the crankshaft with a light coating of Mopart High Temp Grease 4 Align and install converter in oil pump 5 Carefully insert converter in oil pump Then rotate converter back and forth until fully seated in pump gears 6 Check converter...

Page 46: ...rface inside the converter 22 Install torque converter to driveplate bolts 23 Install converter housing access cover 24 Install starter motor and cooler line bracket Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 25 Connect cooler lines Fig 65 to transmission 26 Install transmission fill tube Install new seal on tube before installation 27 Install any exhaust components previously remov...

Page 47: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK 21 176 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 48: ...HYDRAULIC FLOW IN NEUTRAL DR AUTOMATIC TRANSMISSION 48RE 21 177 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 49: ...HYDRAULIC FLOW IN REVERSE 21 178 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 50: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR DR AUTOMATIC TRANSMISSION 48RE 21 179 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 51: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR CONVERTER CLUTCH NOT APPLIED 21 180 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 52: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 181 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 53: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED 21 182 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 54: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 183 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 55: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 21 184 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 56: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 185 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 57: ...HYDRAULIC FLOW IN MANUAL LOW 1 21 186 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 58: ...HYDRAULIC FLOW IN MANUAL SECOND 2 DR AUTOMATIC TRANSMISSION 48RE 21 187 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 59: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING GEAR 21 188 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 60: ... DIMENSIONS Component Metric Inch Front clutch thrust washer reaction shaft support hub 1 55 mm 0 061 in 2 15 mm 0 084 in 2 59 mm 0 102 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in Intermediate shaft thrust plate shaft hub pilot 1 5 1 6 mm 0 060 0 063 in Output shaft thrust washer rear clutch hub 1 3 1 4 mm 0 052 0 054 in 1 75 1 8 mm 0 068 0 070 in 2 1 2 2 mm 0 083 0 085 in Rear c...

Page 61: ...ansmission from downshifting TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fitting cooler line at trans 18 13 Bolt torque convertor 47 35 Bolt clevis bracket to crossmember 47 35 Bolt clevis bracket to rear support 68 50 Bolt driveplate to crankshaft 75 55 Plug front band reaction 17 13 Locknut front band adj 34 25 Bolt fluid pan 13 6 120 Screws fluid filter 4 35 Bolt oil pump 20 15 Bolt ove...

Page 62: ...sure Gauge C 3293SP Dial Indicator C 3339 Valve Spring Compressor C 3422 B Adapter Band Adjuster C 3705 Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer C 3860 A Spring Compressor C 3863 A DR AUTOMATIC TRANSMISSION 48RE 21 191 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 63: ...4962 Spring Compressor and Alignment Shaft 6227 Gauge Bar 6311 Gauge 6312 Retainer 6583 Installer 8114 Socket TRS Mounting Bracket 8581 Installer Seal 9037 21 192 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 64: ...on and then to the kickdown servo As the line pressure reaches the accumulator the com bination of spring pressure and line pressure forces the piston away from the accumulator plate This causes a balanced pressure situation which results in a cushioned band application After the kickdown servo has become immovable line pressure will fin ish pushing the accumulator up into its bore When the large ...

Page 65: ...n appearance and operation to the front band The rear band is slightly different in that it does not use a link bar but is acted directly on by the apply lever This is referred to as a double wrap band design the drum is completely encompassed wrapped by the band The double wrap band pro vides a greater holding power in comparison to the single wrap design OPERATION KICKDOWN FRONT BAND The kickdow...

Page 66: ...g screw 1 3 4 turns 5 Hold adjuster screw in position and tighten locknut to 41 N m 30 ft lbs torque 6 Lower vehicle REAR BAND The transmission oil pan must be removed for access to the rear band adjusting screw 1 Raise vehicle 2 Remove transmission oil pan and drain fluid 3 Loosen band adjusting screw locknut 5 6 turns Be sure adjusting screw turns freely in lever 4 Tighten adjusting screw to 8 N...

Page 67: ...2 inch 12mm 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch in RUN or START posi tions ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK Correct cable adjustment is important to proper interlock operation The gearshif...

Page 68: ...ssure Engine starts must be possible PARK position Apply downward force on the shift arm and remove pressure Engine starts must be possible NEUTRAL position Normal position Engine starts must be possible NEUTRAL position Engine running and brakes applied apply upward force on the shift arm Trans mission shall not be able to shift from neutral to reverse ELECTRONIC GOVERNOR DESCRIPTION Governor pre...

Page 69: ... Averaging of the transducer signal is necessary to reject electrical noise Under cold conditions below 50 degrees F sump the governor pressure solenoid valve response may be too slow to guarantee 0 psi during the 0 5 second calibration pulse Calibration pulses are continued during this period however the transducer output valves are discarded Transducer offset must be read at key on under conditi...

Page 70: ...e ini tial setting for the WOT upshift is below the opti mum engine speed As WOT shifts are repeated the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed After each shift the PCM adjusts the shift point until the optimum speed is reached The PCM also considers vehicle loading grade and engine performance changes due to hig...

Page 71: ...olts to hold governor body to valve body 4 Lubricate o ring on pressure sensor with trans mission fluid 5 Align pressure sensor to bore in governor body 6 Push pressure sensor into governor body 7 Lubricate o ring on pressure solenoid with transmission fluid 8 Align pressure solenoid to bore in governor body Fig 83 9 Push solenoid into governor body Fig 80 Pressure Solenoid and O ring 1 PRESSURE S...

Page 72: ... develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve and clutch operation Foaming also causes fluid expansion which can result in fluid overflow from the transmiss...

Page 73: ...e fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly Improper filling can also raise the fluid level too high When the transmssion has too much fluid the geartrain churns up foam and cause the same condi tions which occur with a low fluid level In either case air bubbles can cause overheating and or fluid oxidation and varnishing ...

Page 74: ... fully drain from the fill tube into the transmission before rechecking the fluid level 10 Check transmission for leaks STANDARD PROCEDURE FLUID AND FILTER REPLACEMENT For proper service intervals Refer to LUBRICA TION MAINTENANCE MAINTENANCE SCHED ULES DESCRIPTION The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts REMOVAL 1 Hoist and support vehicle on safety stan...

Page 75: ... a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert clean funnel in transmission fill tube 2 Add following initial quantity of Mopart ATF 4 to transmission a If only fluid and filter were changed add 3 pints 1 1 2 quarts of ATF 4 to transmission b If transmission was completely overhauled torque converter was replaced or drained and cooler was flushed add 12 pi...

Page 76: ...clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the application of the clutch pack When pressure is released from the piston the spring returns the piston to its fully released position and disengages the clutch The release spring also helps to cushion the application of the clutch assem bly When the clutch is in the process of being r...

Page 77: ... be bent cracked or damaged in any way Replace the piston springs and spring retainer if either are distorted warped or broken Check the lug grooves in the clutch piston retainer The steel plates should slide freely in the slots Replace the piston retainer if the grooves are worn or damaged Also check action of the check ball in the piston retainer The ball must move freely and not stick Replace t...

Page 78: ...t 0 015 0 020 in thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into place Metal tools will cut shave or score the seals 6 Install and position nine clutch piston springs Fig 94 7 Install spring retainer ...

Page 79: ...h its guide against the apply lever Release of the servo at the 2 3 upshift is accom plished by a combination of spring and line pressure acting on the bottom of the larger land of the piston The small piston is used to cushion the application of the band by bleeding oil through a small orifice in the larger piston The release timing of the kickdown servo is very important to obtain a smooth but f...

Page 80: ...red or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reuse suspect parts ASSEMBLY Clean and inspect front servo components 1 Lubricate new o ring and seal rings with petro leum jelly and install them on piston guide and rod Fig 98 Front Servo 1 PISTON RINGS 2 SERVO PISTON 3 O RING 4 SNAP RING 5 PISTON ROD GUIDE 6 SEAL RING 7 SNA...

Page 81: ...ion Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply upward force on the shift arm Transmission shall not be able to shift from neutral to reverse 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 Fig 102 or Fig 103 Fig 101 Front Servo 1 PISTON RINGS 2 ...

Page 82: ...anel opening 3 Snap the cable into the steering column bracket so the retaining ears Fig 107 are engaged and snap the cable eyelet onto the shift lever ball stud 4 Raise the vehicle 5 Place the transmission manual shift lever in the PARK detent rearmost position and rotate prop shaft to ensure transmission is in PARK Fig 104 Gearshift Cable at the Dash Panel 1 GEARSHIFT CABLE 2 GROMMET Fig 105 Gea...

Page 83: ... in any position other than PARK or NEUTRAL or if the engine will not start at all the transmission range sensor may be faulty Gearshift Adjustment Procedure 1 Shift transmission into PARK 2 Release cable adjuster lock tab underneath the steering column Fig 108 to unlock cable 3 Raise vehicle 4 Disengage the cable eyelet from the transmis sion manual shift lever 5 Verify transmission shift lever i...

Page 84: ...r teeth increases in the crescent area and creates a suction at the inlet side of the pump This suction draws fluid through the pump inlet from the oil pan As the clearance between the gear teeth in the crescent area decreases it forces pressurized fluid into the pump outlet and to the valve body Fig 109 Oil Pump Assembly 1 OIL SEAL 7 BOLTS 6 2 VENT BAFFLE 8 1 THRUST WASHER SELECTIVE 3 OIL PUMP BO...

Page 85: ... tion shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Both clearances can be mea sured at the same time by installing the gears in the pump body and measure pump component clearances as follows 1 Position an appropriate piece of Plastigage across both gears 2 Align the plastigage to a flat area on the reac tion shaft housing 3 Install the reaction shaft to the pump housing 4 Separate...

Page 86: ...erwise the rings will either prevent pump installation or break during installation Fig 112 Oil Pump Assembly 1 OIL SEAL 7 BOLTS 6 2 VENT BAFFLE 8 1 THRUST WASHER SELECTIVE 3 OIL PUMP BODY 9 INNER GEAR 4 GASKET 10 OUTER GEAR 5 REACTION SHAFT SUPPORT 11 O RING 6 SEAL RINGS 12 TORQUE CONVERTER SEAL RING Fig 113 Checking Pump Gear Tip Clearance 1 FEELER GAUGE 2 INNER GEAR 3 OUTER GEAR DR AUTOMATIC TR...

Page 87: ... locating retainer groove toward the rear 2 Push bearing onto shaft until the snap ring groove is visible 3 Install snap ring to hold bearing onto output shaft 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle OUTPUT SHAFT REAR BEARING REMOVAL 1 Remove overdrive unit from the vehicle Refer to 21 TRANSMISSION AUTOMATIC OVERDRIVE REMOVAL 2 Remove overdrive geartrain from...

Page 88: ...through the control valves and passageways and enters the clutch through passages at the lower rear portion of the valve body area With pressure applied between the piston retainer and piston the piston moves away from the piston retainer and compresses the clutch pack This action applies the clutch pack allowing torque to flow through the intermediate shaft into the overdrive planetary gear set T...

Page 89: ...ermediate shaft Do not tilt unit during removal Keep it as level as possible 11 If overdrive unit does not require service immediately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment If misalign ment occurs overdrive unit will have to be disassem bled in order to realign splines 12 Remove and retain overdrive piston...

Page 90: ...tainer Fig 123 Fig 120 Overdrive Piston Thrust Bearing Removal Installation 1 THRUST BEARING 2 OVERDRIVE PISTON 3 THRUST PLATE Fig 121 Overdrive Piston Thrust Plate Removal Installation 1 OVERDRIVE PISTON 2 OVERDRIVE PISTON SPACER SELECT FIT Fig 122 Intermediate Shaft Spacer Location 1 INTERMEDIATE SHAFT 2 INTERMEDIATE SHAFT SPACER SELECT FIT Fig 123 Overdrive Piston Removal 1 PISTON RETAINER 2 OV...

Page 91: ...nap ring is located in same groove as wave spring Fig 124 Removing Overdrive Clutch Pack Retaining Ring 1 OVERDRIVE CLUTCH PACK RETAINING RING Fig 125 Overdrive Clutch Pack Removal 1 OVERDRIVE CLUTCH PACK Fig 126 Overdrive Clutch Component Position Typical 1 REACTION PLATE 2 CLUTCH PLATES 3 PRESSURE PLATE 4 CLUTCH DISCS Fig 127 Overdrive Clutch Wave Spring Removal 5 Disc Clutch Only 1 WAVE SPRING ...

Page 92: ...e snap ring that retains rear bearing on output shaft 8 Remove rear bearing from output shaft Fig 133 Fig 129 Access Cover Screw Removal 1 TORX SCREWDRIVER T25 2 ACCESS COVER SCREWS Fig 130 Access Cover And Gasket Removal 1 ACCESS COVER AND GASKET Fig 131 Releasing Bearing From Locating Ring 1 EXPAND BEARING LOCATING RING WITH SNAP RING PLIERS 2 ACCESS HOLE Fig 132 Removing Geartrain 1 GEARTRAIN A...

Page 93: ...ft flange with steel press plates as shown and center assembly under press ram 3 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 134 4 Remove direct clutch pack snap ring Fig 135 5 Remove direct clutch hub retaining ring Fig 136 Fig 134 Geartrain Mounted In Shop Press 1 PRESS RAM 2 SPECIAL T...

Page 94: ...d spring Fig 138 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 139 Fig 137 Direct Clutch Pack Removal 1 SPECIAL TOOL 6227 1 2 DIRECT CLUTCH HUB 3 DIRECT CLUTCH PACK Fig 138 Direct Clutch Hub And Spring Removal 1 DIRECT CLUTCH SPRING 2 DIRECT CLUTCH HUB Fig 139 Removing Sun Gear Thrust Bearing And Planetary Gear 1 PLANETARY GEAR 2 PLANETARY THRUST BE...

Page 95: ...r punch or scriber to make alignment marks 7 Remove direct clutch drum rear retaining ring Fig 142 8 Remove direct clutch drum outer retaining ring Fig 143 Fig 142 Clutch Drum Inner Retaining Ring Removal 1 INNER RETAINING RING 2 DIRECT CLUTCH DRUM 3 ANNULUS GEAR Fig 143 Clutch Drum Outer Retaining Ring Removal 1 OUTER RETAINING RING Fig 140 Overrunning Clutch Assembly Removal Installation 1 OVERR...

Page 96: ...luid pas sages Discard the old case gasket and seals Do not attempt to salvage these parts They are not reus able Replace any of the overdrive unit snap rings if distorted or damaged Minor nicks or scratches on components can be smoothed with crocus cloth However do not attempt to reduce severe scoring on any components with abrasive materials Replace severely scored compo nents do not try to salv...

Page 97: ...he race if either assembly is worn or damaged in any way Replace the shaft pilot bushing and inner bushing if damaged Replace either shaft bearing if rough or noisy Replace the bearing snap rings if distorted or cracked Check the machined surfaces on the output shaft These surfaces should clean and smooth Very minor nicks or scratches can be smoothed with crocus cloth Replace the shaft if worn sco...

Page 98: ...tall bearing if it does not seat squarely 9 Install overrunning clutch in output shaft Fig 152 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with coun terclockwise twisting motion Fig 152 Overrunning Clutch Installation 1 CLUTCH DRUM 2 OVERRUNNING CLUTCH ASSEMBLY 3 EXPANDING TYPE SNAP RING PLIERS 4 CLUTCH DRUM 5 ANNULUS GEAR 6 OVERRUNNING CLUTCH ASSEMBLY SE...

Page 99: ... are fully seated before proceeding 14 Mount assembled output shaft annulus gear and clutch drum in shop press Direct clutch spring hub and clutch pack are easier to install with assem bly mounted in press 15 Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 156 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully se...

Page 100: ...r bore in plate fits over raised splines Plate should be flush with this end of hub Fig 158 b Install first clutch disc with internal splines friction side up followed by a disc with external lugs friction side up Continue alternating internal and external discs until all discs have been installed Fig 158 Correct Position Of Direct Clutch Reaction Plate 1 REACTION PLATE COUNTERBORE 2 DIRECT CLUTCH...

Page 101: ...LY TO AVOID PERSONAL INJURY 19 Position Compressor Tool 6227 1 on clutch hub 20 Compress clutch hub and spring just enough to place tension on hub and hold it in place 21 Slowly compress clutch hub and spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 22 Realign clutch pack on hub and seat clutch discs and plates in clutch dr...

Page 102: ... ring 4 Install reaction plug snap ring Fig 164 Com press snap ring only enough for installation do not distort it 5 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 165 6 Support geartrain on Tool 6227 1 Fig 166 Be sure tool is securely seated in clutch hub Fig 165 Correct Rear Bearing Locating Ring Position 1 CASE ACCESS HOLE 2 TAB ENDS OF LOCATING RING...

Page 103: ... Fig 170 Reac tion ring and wave ring both fit in same ring groove Use screwdriver to seat each ring securely in groove Also ensure that the ends of the two rings are offset from each other 3 Assemble overdrive clutch pack 4 Install overdrive clutch reaction plate first Fig 166 Overdrive Gear Case Installation 1 GEARTRAIN ASSEMBLY 2 GEAR CASE Fig 167 Seating Locating Ring In Rear Bearing 1 EXPAND ...

Page 104: ...netary gear and into pilot bushing in output shaft Be sure tool bottoms against planetary shoulder b Position Gauge Tool 6311 across face of over drive case Fig 172 Then position Dial Caliper C 4962 over gauge tool c Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312 Lock scale in place Remove dial caliper tool and note dista...

Page 105: ...nsor not be installed until after overdrive unit is secured to transmission OVERDRIVE PISTON 1 Install new seals on overdrive piston 2 Stand transmission case upright on bellhous ing 3 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 4 Position Seal Guide 8114 3 on inner edge of overdrive piston retainer 5 Install overdrive piston in overdrive piston retainer by a Aligning loc...

Page 106: ...227 2 Overdrive unit cannot be installed if splines are not aligned If splines have rotated out of alignment unit will have to be disassembled to realign splines 9 Carefully slide Alignment Tool 6227 2 out of overdrive planetary gear and overrunning clutch splines 10 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reaction plug at same ti...

Page 107: ... in the same direction as the inner race they are wedged between the inner and outer races due to the design of the cam In this condition the clutch is locked and acts as one unit DISASSEMBLY 1 Remove the overdrive piston Fig 179 2 Remove the overdrive piston retainer bolts 3 Remove overdrive piston retainer 4 Remove case gasket 5 Tap old cam out of case with pin punch Insert punch through bolt ho...

Page 108: ...on retainer in case Use 3 4 bolts to secure retainer 2 Align and start new clutch cam in the trans mission case Be sure serrations on cam and in case are aligned Fig 181 Then tap cam into case just enough to hold it in place 3 Verify that cam is correctly positioned before proceeding any further Narrow ends of cam ramps should be to left when cam is viewed from front end of case Fig 181 4 Insert A...

Page 109: ...ing cam installation are removed from case 13 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be sure to align governor feed holes in gasket with feed passages in case Fig 186 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer Fig 186 Installing Aligning Case Gasket 1 ...

Page 110: ...of pistons used in an automatic transmission Some pistons are used to apply clutches while others are used to apply bands They all have in common the fact that they are round or circular in shape located within a smooth walled cylinder which is closed at one end and con verts fluid pressure into mechanical movement The fluid pressure exerted on the piston is contained within the system through the...

Page 111: ...ation of Pascal s Law is that regardless of container shape or size the pressure will be maintained throughout as long as the fluid is confined In other words the pressure in the fluid is the same everywhere within the container FORCE MULTIPLICATION Using the 10 PSI example used in the illustration Fig 190 a force of 1000 lbs can be moved with a force of only 100 lbs The secret of force multiplica...

Page 112: ...ve planetary gear assem blies and located in such order A simple planetary gearset consists of three main members The sun gear which is at the center of the sys tem The planet carrier with planet pinion gears which are free to rotate on their own shafts and are in mesh with the sun gear The annulus gear which rotates around and is in mesh with the planet pinion gears NOTE The number of pinion gear...

Page 113: ...m driving shell Fig 196 Note washer position for assembly reference Fig 193 Removing Planetary Snap Ring 1 PLANETARY SNAP RING Fig 194 Removing Front Planetary And Annulus Gears 1 DRIVING SHELL 2 FRONT ANNULUS GEAR 3 FRONT PLANETARY GEAR Fig 195 Disassembling Front Planetary And Annulus Gears 1 FRONT PLANETARY GEAR 2 TABBED THRUST WASHER 3 FRONT ANNULUS GEAR 4 TORLON BUSHING Fig 196 Driving Shell ...

Page 114: ...haft Be sure the oil passages are open and clear Replace the shaft if scored pitted or damaged Inspect the sun gear and driving shell If either component is worn or damaged remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell Then replace the necessary component Replace the sun gear as an assembly if the gear teeth are chipped or worn Also repla...

Page 115: ...in driving shell Note that the large ID chamfer on the sun gear goes forward 3 Install rear annulus gear on intermediate shaft Fig 202 4 Install thrust washer to rear planetary gear Fig 203 using petroleum jelly Be sure washer is seated against corner witht teh tabs completely in the locating holes 5 Install rear planetary gear in rear annulus gear Fig 204 Be sure planetary carrier is seated again...

Page 116: ...m jelly to hold washer in place if desired 10 Install tabbed thrust washer on front plane tary gear Fig 208 Seat washer tabs in matching slots in face of gear carrier Use extra petroleum jelly to hold washer in place if desired 11 Install the torlon bushing onto the front plan etary carrier hub Fig 205 Installing Rear Planetary Thrust Washer 1 REAR PLANETARY GEAR 2 TABBED THRUST WASHER Fig 206 Ins...

Page 117: ...mponents are assembled correctly 15 Install new planetary snap ring in groove at end of intermediate shaft Fig 211 16 Turn planetary geartrain over Position wood block under front end of intermediate shaft and sup port geartrain on shaft Be sure all geartrain parts have moved forward against planetary snap ring This is important for accurate end play check Fig 209 Assembling Front Planetary And An...

Page 118: ...he front clutch pack is needed to hold against the greater torque load imposed onto the rear pack The rear clutch is directly behind the front clutch and is considered a driving component NOTE The number of discs and plates may vary with each engine and vehicle combination Fig 212 Checking Planetary Geartrain End Play 1 OUTPUT SHAFT 2 REAR ANNULUS GEAR 3 FEELER GAUGE Fig 213 Rear Clutch Components...

Page 119: ...ng ring 8 Press input shaft out of retainer with shop press and suitable size press tool Use a suitably sized press tool to support the retainer as close to the input shaft as possible CLEANING Clean the clutch components with solvent and dry them with compressed air Do not use rags or shop towels to dry any of the clutch parts Lint from such materials will adhere to component surfaces and could r...

Page 120: ... of transmission fluid 8 Install clutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 0209 thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into...

Page 121: ...ndicator d Lift the pressure plate until it contacts the snap ring and record the dial indicator reading Clearance should be 0 635 0 914 mm 0 025 0 036 in If clearance is incorrect steel plates discs selective snap ring and pressure plates may have to be changed The selective snap ring thicknesses are 0 107 0 109 in 0 098 0 100 in 0 095 0 097 in 0 083 0 085 in 0 076 0 078 in 0 071 0 073 in 0 060 0...

Page 122: ... from servo piston Fig 218 2 Remove and discard servo piston seal ring CLEANING Remove and discard the servo piston seal ring Fig 219 Then clean the servo components with solvent and dry with compressed air Replace either spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use new ones at assembly ASSEMBLY 1 Lubricate piston ...

Page 123: ...solenoids operate the valves directly which means that the solenoids must have very high outputs to close the valves against the siz able flow areas and line pressures found in current transmissions Fast response time is also necessary to ensure accurate control of the transmission The strength of the magnetic field is the primary force that determines the speed of operation in a par ticular solen...

Page 124: ...hifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive The transmission throttle valve is operated by a cam on the throttle lever The throttle lever is oper ated by an adjustable cable Fig 223 The cable is attached to an arm mounted on the throttle lever shaft A retaining clip at the engine end of the cable...

Page 125: ...throttle body lever Cable end and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in either direction Fig 226 If cable end and attachment stud are misaligned off center cable will have to be adjusted as described in Throttle Valve Cable Adjustment proce dure Fig 225 Throttle Valve Cable at Transmission 1 TRANSMISSION SHIFTER CABLE 2 THROTTLE VALVE CABLE 3 TRANS...

Page 126: ... push the T V cable lock A into the down position Fig 226 This will lock the present T V cable adjustment NOTE Be sure that as the cable is pulled forward and centered on the throttle lever stud the cable housing moves smoothly with the cable Due to the angle at which the cable housing enters the spring housing the cable housing may bind slightly and create an incorrect adjustment 8 Reconnect the ...

Page 127: ... the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system Fig 228 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 ENGINE ROTATION 3 IMPELLER VANES AND COVER ARE INTEGRAL 21 256 AUTOMATIC TRANSMISSION 48RE DR TORQUE CONVERTER Continued ...

Page 128: ... through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 229 Turbine 1 TURBINE VANE 4 PORTION OF TORQUE CONVERTER COVER 2 ENGINE ROTATION 5 ENGINE ROTATION 3 INPUT SHAFT 6 OIL FLOW WITHIN TURBINE SECTION DR AUTOMATIC TRANSMISSION 48RE 21 257 TORQUE CONVERTER Contin...

Page 129: ...is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impeller and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside of the front cover to pro vide this me...

Page 130: ...ce is transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a clockwise direction following the impeller As the fluid is leav ing the trailing edges of the turbine s blades it con tinues in a hindering direction back toward the impeller If the fluid is not redirected before it strikes the impeller it will strike the impeller in a direction t...

Page 131: ...ed by the PCM The torque converter clutch may disengage momentarily when an increase in engine load is sensed by the PCM such as when the vehicle begins to go uphill or the throttle pressure is increased REMOVAL 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 l...

Page 132: ...iods The valve check ball is spring loaded and has an opening pressure of approximately 2 psi The valve is serviced as an assembly it is not repairable Do not clean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates significant amounts of sludge and or clutch par ticles and metal shavings the valve must be replaced...

Page 133: ... component when diagnosis indicates this is necessary Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range REMOVAL 1 Using a plastic trim tool remove the tow haul overdrive off switch retainer from the shift lever Fig 237 2 Pull the switch outwards to release it from the connector in the lever Fig 238 INSTALLATION NOTE There is enough sla...

Page 134: ...he TRS signal The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL providing a ground for the sig nal from the starter relay and the JTEC engine con troller OPERATION As the switch moves through its linear motion Fig 241 contacts slide across a circuit board which changes th...

Page 135: ... suitable hoist 2 Disconnect the vehicle s shift cable from the manual lever 3 With the manual lever in the PARK position the PARK position is with the manual lever moved to the full rearward position measure the resistance between the Park Neutral Position Sense pin of the TRS and the transmission case The resistance should be less than 5 ohms 4 With the manual lever in the NEUTRAL posi tion the ...

Page 136: ...ce should be 59 9 ohms If the resistance is not correct replace the TRS 11 With the manual lever in the SECOND posi tion the SECOND position is with the manual lever moved one detent rearward of the full forward posi tion measure the resistance between the Transmis sion Range Sensor MUX and the Back up Lamp feed pins of the TRS The resistance should be 31 9 ohms If the resistance is not correct re...

Page 137: ...operation Fig 247 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 Fig 244 Remove TRS Mounting Bracket 1 SOLENOID CASE CONNECTOR 2 TRS MOUNTING BRACKET Fig 245 Tighten the TRS Mounting Bracket 1 SOLENOID CASE CONNECTOR 2 TRS MOUNTING BRACKET 3 ADAPTER 8581 Fig 246 Remove ...

Page 138: ...t allow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body a separator plate and transfer plate The valve body contains valves and check balls that control fluid delivery to the torque converter clutch bands and frictional clutches The valve body contains the following components Fig 249 ...

Page 139: ...ATOR VALVE 9 1 2 GOVERNOR PLUG 3 SWITCH VALVE 10 GOVERNOR PLUG COVER 4 REGULATOR VALVE SPRING 11 THROTTLE PLUG 5 KICKDOWN VALVE 12 2 3 GOVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING 21 268 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 140: ...INER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER DR AUTOMATIC TRANSMISSION 48RE 21 269 VALVE BODY Continued ...

Page 141: ...G 2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE COVER 12 THROTTLE PRESSURE SPRING AND PLUG 21 270 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 142: ...R 14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CONVERTER CLUTCH SOLENOID 19 SOLENOID GASKET 10 OVERDRIVE SOLENOID 20 HARNESS DR AUTOMATIC TRANSMISSION 48RE 21 271 VALVE BODY Continued ...

Page 143: ...er Manual Low or Manual 2nd forcing the downshift to 2nd gear regardless of governor pressure 6 Provides a by pass around the front servo orifice so that the servo can release quickly 7 Provides a by pass around the rear clutch orifice so that the clutch can release quickly 8 Directs reverse line pressure through an orifice to the throttle valve eliminating the extra leakage and insuring that Reve...

Page 144: ...o increase Oil pressure on the opposite end of the valve pushes the valve to the right opening the dump and lowering oil pressure The result is spring pressure working against oil pressure to maintain the oil at specific pressures With the engine run ning fluid flows from the pump to the pressure reg ulator valve manual valve and the interconnected circuits As fluid is sent through passages to the...

Page 145: ... spring decreases the size of the metering passage When the size of the metering passage is reduced the pressure rises again and the size of the land is increased again Pressure is regulated by this con stant balance of hydraulic and spring pressure The metering at land 2 establishes the line pres sure throughout the transmission It is varied accord ing to changes in throttle position and the tran...

Page 146: ...Fig 255 Regulator Valve in Drive Position Fig 256 Regulator Valve in Reverse Position DR AUTOMATIC TRANSMISSION 48RE 21 275 VALVE BODY Continued ...

Page 147: ...right After passing the annular groove the fluid is routed to the spring end of the 2 3 shift valve Fluid pressure reacting on the area of land 1 overcomes governor pressure downshifting the 2 3 shift valve into the kickdown or second gear stage of operation The valve is held in the kickdown position by throttle pressure routed from a seated check ball 2 Again if vehicle speed is low enough thrott...

Page 148: ...bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore This pushes the valve upward against the spring and bot toms the valve against the top of the housing With the valve bottomed against the housing the throttle pressure supplied to the valve will be closed off by the bottom land of the limit valve When the supply of throttle pressure ha...

Page 149: ...o the right the middle land of the valve will close off the circuit supplying the throttle pres sure to the right side of the valve When the throttle pressure is closed off the valve will move even far ther to the right allowing line pressure to enter another circuit and energize the front servo applying the front band Fig 261 The governor plug serves a dual purpose It allows the shift valves to m...

Page 150: ...tor piston by the 1 2 shift control valve During the 1 2 upshift this pressure is used to control the kick down servo apply pressure that is needed to apply the kickdown and accumulator pistons Thus the 1 2 shift point is cushioned and the quality is improved During a WOT kickdown kickdown pres sure is applied between the kickdown valve and the 1 2 shift control valve This additional pressure is d...

Page 151: ... pressure to the front clutch After the shift Fig 264 line pressure is directed to the release side of the kickdown servo This releases the front band and applies the front clutch shifting into third gear or direct drive The rear clutch remains applied as it has been in the other gears During a manual 1 or manual 2 gear selec tion line pressure is sent between the two lands of the 2 3 governor plu...

Page 152: ...Fig 264 2 3 Shift Valve After Shift Fig 265 3 4 Shift Valve Before Shift Fig 266 3 4 Shift Valve After Shift DR AUTOMATIC TRANSMISSION 48RE 21 281 VALVE BODY Continued ...

Page 153: ...peed increases pump output The increase in pressure and volume must be regu lated to maintain the balance within the transmis sion To do this throttle pressure is routed to the reaction area on the right side of the throttle pres sure plug in the regulator valve The higher engine speed and line pressure would open the vent too far and reduce line pressure too much Throttle pressure which increases...

Page 154: ...n occurs Fig 268 the pressure regulator valve is supplying torque converter pres sure to the switch valve The switch valve directs this pressure through the transmission input shaft into the converter through the converter back out between the input shaft and the reaction shaft and back up to the switch valve From the switch valve the fluid pressure is directed to the transmission cooler and lubri...

Page 155: ...pply side of the torque converter piston This pressure differential causes the piston to apply against the friction material cutting off any further flow of line pressure oil After the switch valve is shuttled right allowing line pressure to engage the TCC torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits Fig 269 Switch Valve Torque C...

Page 156: ...4 3 downshift until the TCC is completely unlocked and the clutch is disen gaged SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves When the manual valve is positioned in the Drive range throttle pressure acts on the throttle plug of the shuttle valve Fig 262 to move it against a spring increasing the spring force on the shuttle valve During a part or full t...

Page 157: ...mission temperature thermistor Converter clutch overdrive solenoid assembly and harness Governor housing gasket Solenoid case connector O rings 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 Fig 273 5 Remove the transmission range sensor Refer to 21 TRANSMISSION AUTOMATIC T...

Page 158: ... transfer plate 3 Remove retainer plate governor body and gas ket from transfer plate 4 Remove governor pressure sensor from gover nor body 5 Remove governor pressure solenoid by pulling it straight out of bore in governor body Remove and discard solenoid O rings if worn cut or torn 6 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator hous ing Fig 275 Retai...

Page 159: ...OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 278 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLENOID 3 SOLENOID SCREWS 4 GOVERNOR SENSOR WIRES 5 OVERDRIVE SOLENOID 6 HARNESS 7 CASE CONNECTOR Fig 279 Boost Valve Cover Location 1 BOOST VALVE HOUSING AND COVER 2 BOOST VALVE TUBE Fig 280 Boost Valve Components 1 SPRING AND VALVE RETAINER 2 COVER SCREWS 3 BOOST VALVE C...

Page 160: ...gnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 285 Fig 281 Detent Ball Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING Fig 282 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD Fig 283 Throttle Lever E Clip And Washer 1 THROTTLE LEVER SHAFT 2 E CLIP AND WASHER 3 MANUAL SHAFT Fig 284 Manual And Throttle Le...

Page 161: ...g 288 20 Remove kickdown detent kickdown valve and throttle valve and spring Fig 288 21 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remove cen ter and right side housing attaching screws Fig 289 22 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 290 Fig 287 Adjusting Screw Bracket ...

Page 162: ...OVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING Fig 289 Accumulator Housing Screw Locations 1 LOOSEN THIS SCREW 2 REMOVE THESE SCREWS 3 3 4 ACCUMULATOR HOUSING Fig 290 3 4 Shift And Converter Clutch Valve Springs and Plug 1 ACCUMULATOR HOUSING 2 CONVERTER CLUTCH VALVE SPRING 3 CLUTCH VALVE PLUG 4 3 4 SHIFT VALVE SPRING DR AUTOMATIC TRANSMISSION 48RE 21 29...

Page 163: ...t fall out when lower housing and separator plate are removed 27 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 294 Note position of boost valve tube brace for assembly reference 28 Remove lower housing and overdrive separa tor plate from transfer plate Fig 294 Fig 293 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISENGAGE THIS END OF TUBE FIRST 4...

Page 164: ...or plate for assembly reference 33 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 298 Fig 295 Number 10 Check Ball 1 NUMBER 10 CHECK BALL 3 169 Fig 296 Transfer Plate 1 UPPER HOUSING 2 TRANSFER PLATE Fig 297 Upper Housing Separator Plate 1 TRANSFER PLATE 2 UPPER HOUSING SEPARATOR PLATE 3 FILTER SCREEN 4 BRACE Fig 298 Rear Clutc...

Page 165: ...Turn upper housing around and remove limit valve and shift valve covers Fig 302 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 302 9 Remove 1 2 shift control valve and spring Fig 302 10 Remove 1 2 shift valve and spring Fig 302 11 Remove 2 3 shift valve and spring from valve body Fig 302 12 Remove pressure plug cover Fig 302 ...

Page 166: ...INER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER DR AUTOMATIC TRANSMISSION 48RE 21 295 VALVE BODY Continued ...

Page 167: ...G 2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE COVER 12 THROTTLE PRESSURE SPRING AND PLUG 21 296 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 168: ...prings 1 3 4 ACCUMULATOR HOUSING 11 TIMING VALVE COVER 2 3 4 SHIFT VALVE AND SPRING 12 PLUG 3 PLUG 13 3 4 TIMING VALVE AND SPRING 4 SPRING RETAINER 14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CO...

Page 169: ...ten a bent shaft or correct a loose lever Replace these components if worn bent loose or damaged in any way Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a straight edge 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 th...

Page 170: ...oulder bolt switch valve and spring pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer and E clip fluid filter and screws detent ball and spring valve body screws governor pressure solenoid governor pressure sensor and retaining clip park lock rod and E clip ASSEMBLY CAUTION Do not force valves or plugs into place during reasse...

Page 171: ...R 14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CONVERTER CLUTCH SOLENOID 19 SOLENOID GASKET 10 OVERDRIVE SOLENOID 20 HARNESS 21 300 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 172: ...9 4 Install brace plate Fig 309 Tighten brace attaching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in lbs torque Fig 306 3 4 Accumulator and Housing 1 ACCUMULATOR PISTON 2 3 4 ACCUMULATOR HOUSING 3 TEFLON SEALS 4 PISTON SPRING 5 COVER PLATE AND SCREWS Fig 307 Rear Clutch And Rear Servo Check Ball Locations 1 REAR CLUTCH CHECK BA...

Page 173: ... screen is seated in proper housing recess 3 Install the Number 10 check ball into the transfer plate Fig 312 The check ball is approxi mately 4 8 mm 3 16 in in diameter 4 Position lower housing separator plate on transfer plate Fig 313 Fig 310 Check Ball Locations In Upper Housing 1 SMALL DIAMETER CHECK BALLS 5 2 LARGE DIAMETER CHECK BALL 1 Fig 311 Installing Transfer Plate On Upper Housing 1 FIL...

Page 174: ... pressure sleeve throttle plug and spring Insert assembly in upper housing and install cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 3 Install 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring Fig 314 Installing Lower Housing On Transfer Plate And Upper Housing 1 VALVE BODY SCREWS 13 2 LOWER HOUSING 3 UPPER HOUSING 4 TRANSFER PLATE Fig 315 Shuttle...

Page 175: ...y seated before proceeding 8 Install shuttle valve cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 9 Install 1 2 and 2 3 valve governor plugs in valve body 10 Install shuttle valve primary spring and throttle plug 11 Align and install governor plug cover Tighten cover screws to 4 N m 35 in lbs torque Fig 316 Upper Housing Control Valve Locations 1 UPPER HOUSING 8 MANUAL VALVE 2 RE...

Page 176: ...G 2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE COVER 12 THROTTLE PRESSURE SPRING AND PLUG DR AUTOMATIC TRANSMISSION 48RE 21 305 VALVE BODY Continued ...

Page 177: ...d finger tighten three screws that secure tube brace to valve body housings Fig 319 7 Bend tube brace tabs up and against tube to hold it in position Fig 320 8 Tighten all valve body housing screws to 4 N m 35 in lbs torque after tube and brace are installed Tighten screws in diagonal pattern starting at center and working outward Fig 318 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISEN...

Page 178: ...ainer and cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 2 Insert manual lever detent spring in upper housing 3 Position detent ball on end of spring Then hold detent ball and spring in detent housing with Retainer Tool 6583 Fig 323 4 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 5 Align manual lever with...

Page 179: ...SION TRANS AXLE AUTOMATIC VALVE BODY ADJUST MENTS 18 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 19 Attach solenoid case connector to 3 4 accumu lator with shoulder type screw Connector has small locating tang that fits in dimple at top of accumula tor housing Fig 325 Seat tang in dimple before tightening connector screw 20 Install solenoi...

Page 180: ...shaft through seal in case 6 Lubricate seal rings on valve body harness con nector with petroleum jelly 7 Position valve body in case and work end of park lock rod into and through pawl sprag Turn pro peller shaft to align sprag and park lock teeth if nec essary The rod will click as it enters pawl Move rod to check engagement CAUTION It is possible for the park rod to displace into a cavity just ...

Page 181: ...usting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C 3763 between the throttle lever cam and the kickdown valve stem Fig 330 Push the gauge tool inward to compress the kick down valve against the spring and bottom the thro...

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