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Customer Satisfaction Notice #690

Reverse Check Ball and Separator Plate

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Date: October 1996

BEFORE PERFORMING THIS RECALL, CHECK THE DIAL SYSTEM 70 TO VERIFY THE REPAIR HAS NOT BEEN COMPLETED.

Models: 1996 BR Ram Truck

1994 Through 1996 Model Year Dodge Ram (BR) and Dakota (AN) 4X4 Trucks Equipped with an Automatic Transmission and Snow Plow Prop Package (Sales Code -- AHD or AHH) Built Through April 30,1996 (MDH 043OXX)

The vehicles listed above may experience premature reverse band wear when used in snow plow applications. This may lead to a loss of reverse gear. To correct this condition, the transmission valve body upper housing separator plate must be replaced and the reverse servo check ball must be removed.

Details of this service action are explained in the following sections.

Service Procedure Videotape

No videotape of the service procedure for this notification will be provided.

Subject:

Customer Satisfaction Notification #690 - Reverse Check Ball and Separator Plate

Parts:

Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand.

Each involved dealer to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Separator Plate Packages, PN CECBS900, to service 25% of those vehicles.

Each parts package contains the following components:

     Quantity      Description
1 Valve Body Separator Plate
1 Gasket, Transmission Oil Pan
1 Instruction Sheet

Owner Notification and Service Scheduling:

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed.

Service Procedure:

A. Remove Transmission Valve Body Assembly:

1. Shift transmission into neutral.

2.  Raise vehicle on an appropriate hoist

3. For Dakota (AN) vehicles: Disconnect the exhaust Y-pipes from the exhaust manifolds and then lower the front part of the exhaust system.

4. Remove the gearshift and throttle levers from the valve body manual lever shaft.

5. For 46RE Transmission: Disconnect the wires from the solenoid case connector (Figure 1).

6. Position a drain pan under the transmission oil pan.

7. Remove the transmission oil pan and gasket.

8. Remove the three screws that secure the fluid filter to the valve body and remove the filter.

9. Remove the bolts that attach the valve body to the transmission case.

10. Lower the valve body enough to remove the accumulator piston and springs.

11. Work the manual lever shaft and electrical connector out of the transmission case.

12. Lower the valve body, then rotate the valve body away from the case, pull the park rod out of the sprag and then remove the valve body (Figures 2 and 3).

fig 1 fig 2 & 3

B. Valve Body Disassembly:

CAUTION: Do not clamp any valve body component In a vise. This can damage the component and result in unsatisfactory operation after assembly and Installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components into or out of place. The valves and valve body housings will be damaged if force Is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed.

1. For 46RE transmissions: Disconnect the wires from the governor pressure sensor and solenoid (Figure 4).

2. For 46RE transmissions: Remove the screws that attach the governor body and the retainer plate to the transfer plate (Figure 5).

3. For 46RE transmissions: Remove the retainer plate, governor body and gasket from the transfer plate (Figure 6). Save the gasket for later reuse.

fig 4 fig 5 fig 6

4. Bend back the tabs on the boost valve tube brace (Figure 7).

5. Remove the boost valve connecting tube (Figure 8). Disengage the tube from the upper housing port first. Then rock the opposite end of the tube back and forth to work it out of the lower housing.

CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body. Loosen and remove the tube by hand only.

6. Turn the valve body over and remove the screws that attach the overdrive/converter solenoid assembly to the valve body (Figure 9).

fig 7 fig 8 fig 9

7. The valve body lower housing should be facing upward (Figure 10). In this position, the check balls in the upper housing will remain in place and not fall out when the lower housing and separator plate are removed.

8. Remove the screws that attach the valve body lower housing to the upper housing and transfer plate. (Figure 10). Note the position of the boost valve tube brace for assembly reference.

9. Remove the lower housing and overdrive separator plate from the transfer plate (Figure 10).

10. Remove the transfer plate from the upper housing (Figure 11).

CAUTION: Do NOT turn the upper housing over or check balls will fall out.

11. Turn the transfer plate over so that the upper housing separator plate is facing upward.

12. Remove the brace plate from the upper housing separator plate and transfer plate (Figure 12).

13. Remove the upper housing separator plate from the transfer plate (Figure 13). Note the position of the filter in the separator plate for assembly reference.

14. Cover the rear clutch check ball with your thumb and then turn the transfer plate over just enough to remove the reverse servo check ball from the transfer plate (Figure 14). Discard the removed check ball.

C. Valve Body Assembly:

1. Remove the filter screen from the upper housing separator plate and install it on the supplied upper housing separator plate (Figure 15). Discard the old separator plate.

2. Align and position the provided upper housing separator plate on the transfer plate (Figure 16).

3. Install the brace plate (Figure 16). Tighten the brace plate attaching screws to 35 in-lbs (4 N-m).

4. Install the remaining separator plate attaching screws. Tighten the attaching screws to 35 in-lbs (4 NM).

5. Position the upper housing so that the internal passages and check ball seats are facing upward. Make sure that the seven (7) check balls are properly positioned (Figure 17).

6. Position the assembled transfer plate and upper housing separator plate on the upper housing (Figure 18). Be sure that the filter screen is seated in the proper housing recess.

7. Position the lower housing separator plate on the transfer plate (Figure 19).

8. Install the lower housing on the assembled transfer plate and upper housing (Figure 20).

9. Install the tube brace and start all valve body screws by hand. Then tighten the screws evenly to 35 in-lbs (4 NM). Start at the center and work out to the sides when tightening the screws.

10. Position the valve body assembly so that the lower housing is facing upward (Figure 21).

11. Lubricate the boost valve tube ends and housing ports with clean transmission fluid.

12. Install the tube starting in the lower housing port first. Then swing the tube downward and work the opposite end of the tube into the upper housing port (Figure 21).

13. Seat each end of the tube in the housings.

14. Bend the tube braces up and against the tube to hold it in position (Figure 22).

15. Reinstall the overdrive solenoids.

CAUTION: For 46RE transmissions: Do not turn the small screw at the end of the governor pressure solenoid valve for any reason (Figure 23). Turning the screw in either direction will ruin the solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is not serviceable. Do not try to remove the filter as this will damage the solenoid valve housing.

16. For 46RE transmissions: Turn the valve body assembly over so that the accumulator side of the transfer plate is facing down.

17. For 46RE transmissions: Position the governor body gasket on the transfer plate (Figure 24).

 

18. For 46RE transmissions: Connect the wiring harness to the governor pressure sensor and solenoid.

19. For 46RE transmissions: Install the retainer plate on the governor body and around the solenoid (Figure 25), Be sure the solenoid connector is positioned in the retainer cutout.

20. For 46RE transmissions: Align the holes in the governor body and the transfer plate. Then install and tighten the governor body screws to 35 in-lbs (4 NM).

D. Install Valve Body:

1. Check the condition of the 0-ring seals on the valve body harness connector (Figure 26). Replace the seals on the connector body if they are cut or worn.

2. Check condition of the manual lever shaft seal in the transmission case. Replace the seal if the lip is cut or worn.

3. Check the condition of the seals on the accumulator piston. Install new seals if necessary.

4. Place the valve body manual lever in the low (1 position) so that the ball on the park lock sprag will be easier to install in the sprag.

5. Lubricate the shaft of the manual lever with petroleum jelly.

6. Lubricate the seal rings on the valve body harness connector with petroleum jelly.

7. Position the valve body in the case and work the end of the park lock rod into and through the pawl sprag. Turn the propeller shaft to align the sprag and park lock teeth if necessary. The rod will click as it enters the pawl. Move the rod to check engagement.

CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure that the rod is actually engaged In the pawl and has not displaced into this cavity.

8. Install the accumulator springs and piston into the case. Then swing the valve body over the piston and outer spring to hold it in place.

9. Align the accumulator piston and outer spring, manual lever shaft and electrical connector in the case.

10. Seat the valve body in the case and install one or two bolts to hold it in place.

11. Install the remaining valve body bolts. Tighten the valve body bolts alternately and evenly to 100 in-lbs (11 N-m).

12. Install the fluid filter on the valve body. Tighten the filter screws to 35 in-lbs (4 NM).

NOTE: Inspect the filter and replace it if necessary.

13. Install the throttle and gearshift levers on the valve body manual lever shaft.

14. Check and adjust the front and rear bands if necessary.

15. Connect the solenoid case connector wires.

16. Install the transmission oil pan using the provided gasket. Tighten the pan bolts to 13 ft-lbs (17 NM).

17. For Dakota (AN) vehicles: Reconnect the exhaust Y-pipes to the exhaust manifolds.

18. Lower the vehicle.

19. Fill the transmission with Mopar ATF Plus, type 7176, fluid or equivalent.

20. Check and adjust the gearshift and throttle valve cables if necessary.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

    Labor Operation  
Number
Time
  Allowance  
Replace separator plate and remove check ball:    
Ram Truck (BR) 21690182 1.7 hours
Dakota (AN) 21690183 2.2 hours

Add the cost of the parts plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return

Not required.


Thanks to Bob Bergevin and Barry Drodge for supplying this bulletin.

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This page was edited on: May 3, 2004