Dodge Durango (DN). Manual — part 116
45RFE AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
45RFE AUTOMATIC TRANSMISSION . . . . . . . . . 331
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 332
ELECTRONICALLY MODULATED
CONVERTER CLUTCH ENGAGEMENT. . . . . . 336
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
INPUT CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . 341
HOLDING CLUTCHES . . . . . . . . . . . . . . . . . . . . 342
PLANETARY GEARTRAIN . . . . . . . . . . . . . . . . . 343
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 344
OVERDRIVE OFF SWITCH . . . . . . . . . . . . . . . . 345
TRANSMISSION CONTROL MODULE . . . . . . . . 346
SOLENOID AND PRESSURE SWITCH
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
BATTERY FEED (TCM). . . . . . . . . . . . . . . . . . . . 349
TRANSMISSION CONTROL RELAY . . . . . . . . . . 350
PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . 350
INPUT AND OUTPUT SPEED SENSORS . . . . . . 350
LINE PRESSURE CONTROL . . . . . . . . . . . . . . . 351
THROTTLE POSITION SENSOR . . . . . . . . . . . . 351
TRANSMISSION RANGE SENSOR. . . . . . . . . . . 351
TRANSMISSION TEMPERATURE SENSOR . . . . 351
SOLENOIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
SOLENOID SWITCH VALVE . . . . . . . . . . . . . . . . 352
DIAGNOSIS AND TESTING
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 352
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 352
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 352
45RFE AUTOMATIC TRANSMISSION
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . . 353
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . 353
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 353
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 354
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 354
AIR TESTING TRANSMISSION CLUTCH
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 356
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 356
SERVICE PROCEDURES
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . 356
FLUID AND FILTER REPLACEMENT . . . . . . . . . 357
TRANSMISSION FILL PROCEDURE. . . . . . . . . . 358
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 358
FLUSHING COOLERS AND TUBES . . . . . . . . . . 359
TRANSMISSION QUICK LEARN PROCEDURE . 359
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 359
REMOVAL AND INSTALLATION
INPUT SPEED SENSOR. . . . . . . . . . . . . . . . . . . 360
OUTPUT SPEED SENSOR . . . . . . . . . . . . . . . . . 360
LINE PRESSURE SENSOR . . . . . . . . . . . . . . . . 360
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
SOLENOID AND PRESSURE SWITCH
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 362
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 364
OIL PUMP FRONT SEAL . . . . . . . . . . . . . . . . . . 365
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . 365
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 366
DISASSEMBLY AND ASSEMBLY
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 366
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
INPUT CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . 381
4C RETAINER/BULKHEAD . . . . . . . . . . . . . . . . . 386
PLANETARY GEAR SET . . . . . . . . . . . . . . . . . . 387
LOW/REVERSE CLUTCH . . . . . . . . . . . . . . . . . . 387
CLEANING AND INSPECTION
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 391
LOW/REVERSE CLUTCH ASSEMBLY . . . . . . . . 391
ACCUMULATOR. . . . . . . . . . . . . . . . . . . . . . . . . 391
OIL PUMP AND REACTION SHAFT SUPPORT. . 391
PLANETARY GEARTRAIN . . . . . . . . . . . . . . . . . 392
ADJUSTMENTS
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 392
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . 392
SPECIFICATIONS
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 412
SPECIAL TOOLS
45RFE TRANSMISSION . . . . . . . . . . . . . . . . . . . 412
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45RFE AUTOMATIC TRANSMISSION
DN
DESCRIPTION AND OPERATION
45RFE AUTOMATIC TRANSMISSION
DESCRIPTION
The 45RFE automatic transmission is a sophisti-
cated, multi-range, electronically controlled transmis-
sion
which
combines
optimized
gear
ratios
for
responsive performance, state of the art efficiency
features and low NVH. Other features include driver
adaptive shifting and three planetary gear sets to
provide wide ratio capability with precise ratio steps
for optimum driveability. The three planetary gear
sets also make available a unique alternate second
gear ratio. The primary 2nd gear ratio fits between
1st and 3rd gears for normal through-gear accelera-
tions. The alternate second gear ratio (2prime) allows
smoother 4–2 kickdowns at high speeds to provide
2nd gear passing performance over a wider highway
cruising range.
The hydraulic portion of the transmission consists
of the transmission fluid, fluid passages, hydraulic
valves, and various line pressure control components.
The primary mechanical components of the trans-
mission consist of the following:
• Three multiple disc input clutches
• Three multiple disc holding clutches
• Five hydraulic accumulators
• Three planetary gear sets
• Dual Stage Hydraulic oil pump
• Valve body
• Solenoid pack
The TCM is the “heart” or “brain” of the electronic
control system and relies on information from vari-
ous direct and indirect inputs (sensors, switches, etc.)
to determine driver demand and vehicle operating
conditions. With this information, the TCM can cal-
culate and perform timely and quality shifts through
various output or control devices (solenoid pack,
transmission control relay, etc.).
TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas-
ket surface (Fig. 1). Refer to this information when
ordering replacement parts. A label is attached to the
transmission case above the stamped numbers. The
label gives additional information which may also be
necessary for identification purposes.
GEAR RATIOS
The 45RFE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:1
2nd Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
OPERATION
The 45RFE offers full electronic control of all auto-
matic up and downshifts, and features real-time
adaptive closed-loop shift and pressure control. Elec-
tronic shift and torque converter clutch controls help
protect the transmission from damage due to high
temperatures, which can occur under severe operat-
ing conditions. By altering shift schedules, line pres-
sure, and converter clutch control, these controls
reduce heat generation and increase transmission
cooling.
To help reduce efficiency-robbing parasitic losses,
the transmission includes a dual-stage transmission
fluid pump with electronic output pressure control.
Under most driving conditions, pump output pres-
sure greatly exceeds that which is needed to keep the
clutches applied. The 45RFE pump-pressure control
system monitors input torque and adjusts the pump
pressure accordingly. The primary stage of the pump
works continuously; the second stage is bypassed
when demand is low. The control system also moni-
tors input and output speed and, if incipient clutch
slip is observed, the pressure control solenoid duty
cycle is varied, increasing pressure in proportion to
demand.
Fig. 1 Transmission Part And Serial Number
Location
DN
45RFE AUTOMATIC TRANSMISSION
21 - 331
A high-travel torque converter damper assembly
allow earlier torque converter clutch engagement to
reduce slippage. Needle-type thrust bearings reduce
internal friction. The 45RFE is packaged in a one-
piece die-cast aluminum case. To reduce NVH, the
case has high lateral, vertical and torsional stiffness.
It is also designed to maximize the benefit of the
structural dust cover that connects the bottom of the
bell housing to the engine bedplate, enhancing over-
all power train stiffness. Dual filters protect the
pump and other components. A pump return filter is
added to the customary main sump filter. Indepen-
dent lubrication and cooler circuits assure ample
pressure for normal transmission operation even if
the cooler is obstructed or the fluid cannot flow due
to extremely low temperatures.
The hydraulic control system design (without elec-
tronic assist) provides the transmission with PARK,
REVERSE, NEUTRAL, SECOND, and THIRD gears,
based solely on driver shift lever selection. This
design allows the vehicle to be driven (in “limp-in”
mode) in the event of a electronic control system fail-
ure, or a situation that the Transmission Control
Module (TCM) recognizes as potentially damaging to
the transmission.
The TCM also performs certain self-diagnostic
functions and provides comprehensive information
(sensor data, DTC’s, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
FLUID
NOTE: Refer
to
the
maintenance
schedules
in
Group 0, Lubrication and Maintenance for the rec-
ommended maintenance (fluid/filter change) inter-
vals for this transmission.
NOTE: Refer to Service Procedures in this group
for fluid level checking procedures.
DESCRIPTION
Mopar
t ATF Plus 3, Type 7176, automatic trans-
mission fluid is the recommended fluid for Daimler-
Chrysler automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar
t ATF Plus 3, Type 7176, automatic trans-
mission fluid when new is red in color. The ATF is
dyed red so it can be identified from other fluids used
in the vehicle such as engine oil or antifreeze. The
red color is not permanent and is not an indicator of
fluid condition. As the vehicle is driven, the ATF will
begin to look darker in color and may eventually
become brown. This is normal. A dark brown/black
fluid accompanied with a burnt odor and/or deterio-
ration in shift quality may indicate fluid deteriora-
tion or transmission component failure.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various “special” additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additives must not be used. The use of trans-
mission “sealers” should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fig. 2) is a hydraulic device
that couples the engine crankshaft to the transmis-
sion. The torque converter consists of an outer shell
with an internal turbine, a stator, an overrunning
clutch, an impeller and an electronically applied con-
verter clutch. The converter clutch provides reduced
engine
speed
and
greater
fuel
economy
when
engaged. Clutch engagement also provides reduced
transmission
fluid
temperatures.
The
converter
clutch engages in third gear. The torque converter
hub drives the transmission oil (fluid) pump and con-
tains an o-ring seal to better control oil flow.
The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.
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45RFE AUTOMATIC TRANSMISSION
DN
DESCRIPTION AND OPERATION (Continued)
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
IMPELLER
The impeller (Fig. 3) is an integral part of the con-
verter housing. The impeller consists of curved
blades placed radially along the inside of the housing
on the transmission side of 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 member of the system.
TURBINE
The turbine (Fig. 4) is the output, or driven, mem-
ber of the converter. The turbine is mounted within
the housing opposite the impeller, but is not attached
to the housing. The input shaft is inserted through
the center of the impeller and splined into the tur-
bine. The design of the turbine is similar to the
impeller, except the blades of the turbine are curved
in the opposite direction.
Fig. 2 Torque Converter Assembly
Fig. 3 Impeller
1 – ENGINE FLEXPLATE
2 – OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
3 – IMPELLER VANES AND COVER ARE INTEGRAL
4 – ENGINE ROTATION
5 – ENGINE ROTATION
DN
45RFE AUTOMATIC TRANSMISSION
21 - 333
DESCRIPTION AND OPERATION (Continued)
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