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Identification Oil Pressure Checks

O.D. Clutch
48RE Forward Pressure
D Min = 54-60 Psi
Max = 95 1st 2nd 3rd unlocked

Lockup or 4th causes Hi-boost

3rd with lockup 120-170
4th gear at 1/2 - 3/4 throttle 140 PSI
4th gear full throttle 155 -170 PSI

Forward Pressure
Governor

Identification
See Valve Body data
on page two.
Four pressure ports on
this side of the trans.

Governor is 0 PSI at stop

and climbs with MPH Rear Servo

Front Servo

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Identification 2003-05 48RE: To increase lockup

holding capacity the 48RE has higher
pressure than the 42 to 47 RE models.
Max pressure: 48RE is prox 170.
The 42-47REs it is prox 135.
More pressure data, see page one.

Has vent here with

No vent here
Spring visible.

High Pressure Low Pressure

48RE 42 to 47RE

48RE Valve body and a TFOD-Jr kit is

Perfect for hopped up Diesels.
Plastic or hard chromed
rings are best for this trans.

Let us hear from you, Tech Team

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Fast Reference
Park rod snap ring

Remove park rod snap ring to

remove the VB from the case.

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Fast Reference

This Kit is About

Preventing Morning Sickness
And Crisper Shifts

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Fast Reference OD Overrunning Clutch

Inner Race freewheels

Hold drum in direction of arrow.

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Fast Reference Low Overrunning Clutch

Low and reverse

drum should free-
wheel in the direc-
tion of the arrow.

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Fast Reference
Clutch Clearances
Overdrive = .090 .110
OD housing Rear Clutch = .016 .036"
Front Clutch = .070 .129

Remove .100 round retaining ring

from OD housing and then use
a .100 drill between OD piston and
top OD steel plate.
Adjust selective OD shim until drill
will just fit between piston and steel.
Then reinstall .100 round snap ring.

.100 drill

OD piston
More OD data
see pages 51-55.

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Fast Reference Air Checks

Vent

Assemble the front &

rear drums and the
torque converter and
the use the following
holes for air checking.

Converter rear
Pump suction
Converter front
Pump suction
Front clutch
Rear clutch

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Fast Reference Air Checks

3rd Clutch Apply Converter front release
Pump Suction
Fwd Clutch Apply Converter rear apply
Pump Pressure

To Cooler

Front Servo
Release

Front Servo
Apply

Rear Servo
Apply

Line pressure
to Accumulator OD Clutch Apply

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Fast Reference Band Adjustments

Front band adjustment:

Back lock nut off several turns.
Use Torx T40 and tighten band to
72 in lb then back off 1 3/4 turns.
Torque locking nut 25 ft lb

Rear band adjustment:

Back lock nut off several turns.
Tighten band to 72 in lb then back off 3 turns.
Torque locking nut 30 ft lb

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Pan & Filter

Fast Reference

Torque 13 MM x .950"
pan bolts to 13 ft lbs.
Pan Gasket
(reusable)

Pan

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Fast Reference

Torx T25 x 2.637" filter screws

Torque filter screws to

35 inch lbs

Filter gasket

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Valve Body Valve body to Case Bolts

Valve Body to case bolts.

7/16" torque to 100 in lbs.
B B

B
See next page for parking
A pawl rod snap ring removal.
This allows the VB to be re-
A moved from the case.

A
C C
"A" 1.262 bolts 3 pieces

C
C
"B" 1.887 bolts 3 pieces

"C" 2.412 bolts 4 pieces

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Valve Body

Park rod snap ring

Remove park rod snap ring to

remove the VB from the case.

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Valve Body Valve Body Screws

D Torx T25 valve body screw.

C
Torque to 35 in lbs.
D D
D
D
D
D D
D
D D
D
E
D

"A" .550 screw 1 piece

"B" .725 screw 1 piece

"C" 1.712 screws 3 pieces

C "D" 2.187 screws 13 pieces

C
"E" 2.637 screw 1 piece

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Valve Body

Valve body screws located on pressure

regulator adjusting bracket.

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Valve Body Valve Body Section ID

Lower housing

Transfer plate

Tube grace

Upper housing

Boost valve tube

Transfer plate

Upper housing

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Valve Body
Governor body gasket
TCC solenoid 3-4 solenoid

Governor pressure sensor

Governor pressure solenoid

Governor body

Governor retainer plate

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Valve Body

Pressure regulator spring Remove

3 screws

Line pressure screw

Switch
valve
spring

Adjusting screw bracket

Throttle pressure
adjusting screw

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Lower housing
Valve Body

Governor pressure solenoid

Case connector

Governor pressure sensor

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Valve Body Internal Harness

.840 shouldered screw

Torque screws to 35 in lb

Case connector

3-4 solenoid

TCC solenoid

Governor
Governor
pressure
pressure
solenoid
sensor
Three .700 screws

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Valve Body

1.939x.395x.035
3-4 timing

.737 screws
torque 35 in lb
1.736x.390x.032

3-4 quick fill

Plug

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Valve Body

Lower Housing

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Valve Body

3-4 accumulator
housing
.737 screws
torque 35 in lb

3-4 shift 2.586x.552x.041

Converter clutch 1.925x.397x.035 Plug

Converter clutch timing 1.909x.389x.033

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Valve Body

3-4 accumulator
housing

3-4 accumulator
housing cover
3-4 accumulator
piston

.550 screws
torque to 35 in lb
2.342x.951.x135

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Valve Body Lower Housing

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Valve Body

Overdrive
separator
plate

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Valve Body

Transfer plate

Governor
body

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Valve Body

Hold down plate

Install filter through

other side of plate.

Install five .550

long screws

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Valve Body Separator plate

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Valve Body

Transfer plate

"A" Install .250 plastic rear servo ball.

"B" Install .250 steel rear clutch ball.

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Valve Body

Install 3/16"
steel ball at
this location.

Transfer plate

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Valve Body

Upper housing Limit valve

housing

Manual valve

Throttle lever

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Valve Body

Upper body

Throttle lever .050 washer

.026 snap ring

.343 steel ball and

1.100x.287x.035 spring

Manual lever assembly

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2-3 governor plug

Valve Body

.937x.525x.041 .026 snap ring

Install .550 screws
Torque to 35 in lb Plug

Shuttle

1.109x.347x.047
1-2 governor plug

Manual valve

.890 Smaller hole

this side.
Kickdown 1.287x.375x.050 Throttle

2.537x637x.062 Pressure regulator

Switch
.570 1.412x.408x.040

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Valve Body

Upper body

B
B
"A" Install .343 plastic ball.
"B" Install .250 plastic balls.

B B
A

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Valve Body
Three 1.150 cover screws
Limit valve housing torque to 35 in lb

1-2 shift .982x.627x.048

2-3 throttle plug

2-3 shift .900x.375x.035 Cover

2-3 shift control

1.862x.500x.041
Limit valve

.825x.279x.031
Plug sleeve
1.450x.512x.035
Retainer

Throttle pressure plug Two .550 cover screws

torque to 35 in lb

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Sooner or later the retainer breaks . Valve Body

If just one leg breaks it will have a
lockup and burn the converter. If two Cover plate
legs break it will cause total burn up.

Retainer

Six .550 screws

Three .550
torque to 35 in lb.
screws 35 in lb.

Retainer
Lockup Boost valve

.937x.275x.029 Plug

Save a comeback
Get new retainer.

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Bands-Pistons 2nd Accumulator and 2nd Struts

2nd band
2nd band strut anchor

2nd accumulator

1.525x1.362x.154

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Bands-Pistons Servos and Apply Arms

Apply arm pin

1/4 drive
screw

Apply arm ratio

Apply arm

.072 washer 2nd piston

2.825x.225x.162
pin
Snap
ring
1.250x787x.052
Cover .050 snap ring
Reverse
Retainer piston .042
snap
pin ring
Snap
ring

1.487x1.337x.180
2.400x2.075x150
Apply arm

pin

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Band Adjustments
Bands-Pistons

Front band adjustment:

Back lock nut off several turns.
Use Torx T40 and tighten band to
72 in lb then back off 1 3/4 turns.
Torque locking nut 25 ft lb

Rear band adjustment:

Back lock nut off several turns.
Tighten band to 72 in lb then back off 3 turns.
Torque locking nut 30 ft lb

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Pump Pump Body

Seven pump bolts

torque to 15 ft lb.

Converter seal

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Pump

Six pump bolts torque

to 15 ft lb.

Converter seal

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Pump Assembly
Inner gear has dimples on both sides.
Long Chamfer with no step
faces torque converter.

Dimple on outer pump gear faces up.

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Pump

Pump pocket needs

to be scratch free.

Bushing should be
staked as shown.

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Clutch Packs Front Clutch

.086 friction .086 friction .086 friction .086 friction
.280 press plate .086 friction

.052 wavy
snap ring

.086 steel
.086 steel
.086 steel .086 steel
.086 steel
Clearance should
be .070-.129
Measure at high spot
of wavy snap ring

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Front Clutch
Clutch Packs

Retainer Nine 1.412x525x072

Stack spring as shown on .062 snap return springs
piston. Stack 3 on a post
then skip 2 as shown.

piston Drum

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Clutch Packs Rear Clutch

.065 friction .065 friction .443 back plate
.280 pressure plate .065 friction .065 friction
faces as shown

.089 selective
snap ring

.068 steel .068 steel .068 steel

Clearance should
be .016-.036.
Check between
snap ring and
pressure plate.

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Clutch Packs Rear Clutch

.100 plastic spacer

.051 wavy snap ring Piston spring

Rear
clutch
drum

Piston Clutch hub and

input shaft

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Clutch Packs Rear Clutch

Rear clutch drum Clutch hub and
Piston spring .100 plastic spacer
input shaft Piston

.051 wavy snap ring

Clutch hub and

.051 wavy snap ring
input shaft

Rear
clutch
drum

.100 plastic spacer

Piston spring

Piston

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Clutch Packs Overdrive Clutch

.088 friction
.088 friction .088 friction
.088 friction .088 friction .088 friction .120
.073 wire
snap ring

.068 steel .235 pressure plate

.068 steel .068 steel Faces as shown.

.068 steel .068 steel .068 steel

Some models use 5 frictions and have

an additional wavy case snap ring.

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Clutch Packs OD Direct Clutch

.050 single sided
.218 stepped
clutches with internal
pressure plate.
and external splines.
Step faces up.

Start with internal an internal splined plate

and end with an internal splined plate.
Install 23 plates total.
12 Internal spline plates and 11 external
spline plates. .216 pressure plate
.079 waved Be sure to alternate one internal and then faces as shown.
snap ring one external plate.

Single sided plates have fric-

tion on one side and are
steel on the other.

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Clutch Packs
Top stepped .218 pressure plate.
.087

1.560 total
height

Single sided or traditional friction steel

clutch plates will work just make sure
the total heights are the same. Bottom stepped .216
pressure plate.
.104

.100
OD direct drum
2.730 overall

1.908
2.500

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Clutch Packs
A press must be used to remove the two snap rings.

Remove the OD direct

clutch snap ring.

Remove the sun

gear snap ring.

To reassemble, install the sun gear snap ring then remove

from the press and install the OD direct clutch pack.
Then place back in the press and install the OD direct
clutch snap ring.

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Clutch Packs

Remove .100 round retaining ring

from OD housing and then use
a .100 drill between OD piston and
top OD steel plate.
Adjust selective OD shim until drill
will just fit between piston and steel.
Then reinstall .100 round snap ring.

.100 drill

OD piston

OD housing

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Low Overrunning Clutch

Low and reverse

drum should free-
wheel in the direc-
tion of the arrow.

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OD Overrunning Clutch

Inner Raceshould free-

wheel direction of arrow.
Hold drum

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Internal Parts Internal Components

Pump body
Plastic
Reaction shaft
selective
Pump gears washer

2nd band

Front drum
Rear drum Snap Front
Plastic Steel
ring planetary
washer washer

Input shaft

Selective Six tab

washer thrust
washer

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Internal Parts

Front
Six tab
annulus Six tab Sun gear shell Six tab
thrust
gear thrust thrust
Plastic washer
washer washer
washer

Rear
annulus
gear
Snap
ring
Intermediate shaft

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Internal Parts Rear band

Low/Rev Drum
Low roller clutch
Plastic Washer

Snap ring

Case

Park rod

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Internal Parts

Case Rear
OD housing gasket
band
anchor

OD piston retainer OD piston Selective .214 OD shim.

Roller bearing inner

lip faces away from
selective OD shim.

1.212 OD piston housing

bolts torque to 13 ft lb

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Internal Parts
Overdrive clutch pack .078 case snap ring

If only 5 OD clutch frictions will use a wavy

snap ring on top of the .078 case snap ring.
Direct clutch pack

.073 snap ring

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Internal Parts
OD planetary
Direct clutch hub
4.045x3.884x.438 Spring plate
Sun gear

Roller bearing
.063 snap ring inner lip faces
planetary.

Direct clutch drum .100 retaining ring .100 retaining ring

OD annulus gear

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Internal Parts
.095 snap ring
Roller bearing
Overrunning clutch hub inner lip faces Output shaft
output shaft

Overrunning clutch

.100 snap ring

Roller bearing
.093 snap ring

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Internal Parts

OD housing 7/16 OD housing bolts 1.762 Access cover screws.

long torque to 25 ft lb Torque to 35 in lb.

Access cover & gasket

Speed sensor

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Case Connector

Thermistor = 1000 ohms at room temp.

OD Solenoid = 31.5 ohms and is normally open.
TCC Solenoid = 31.5 ohms and is normally open.
7 6 5
Governor Pressure Solenoid = 3.9 ohms and is normally open.

1. TCC, Gov. and shift solenoid 12V common positive.

2. 5 Volt feed to governor pressure sensor.
1 3. Ground for governor pressure sensor and thermistor.
4
4. Gov. pressure signal to the TCM.
5. Variable ground to gov. pressure solenoid.
6. Ground from TCM to OD. solenoid.
7. Ground from the TCM to the converter clutch solenoid.
2 8 3
8. Temp. sensor ( Thermistor ) signal to the TCM.

Notes: TCM will inhibit 4th gear if temperatures are below -30 F or above 260 F.
No ground or voltage to governor solenoid = high gov. oil pressure.
Gov. oil pressure should be 0 psi at a stop.

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Lever Switch
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Torque Specifications

Torque Specifications
Bolt, valve body to case 100 in lb
Sensor, trans speed 20 ft lb
Screw, solenoid wiring connector 35 in lb
Screw, solenoid to transfer plate 35 in lb
Bracket, transmission range sensor mounting 25 in lb
Screw, transmission range sensor to mounting bracket 45 in lb
Screws, fluid filter 35 in lb
Bolt, oil pump 15 ft lb
Bolt, O/D to trans. 25 ft lb
Bolt, O/D piston retainer 13 ft lb
Plug, pressure test port 10 ft lb
Bolt, reaction shaft support 15 ft lb
Locknut, rear band 30 ft lb
Fitting, cooler line at transmission 13 ft lb
Bolt, torque converter 35 ft lb
Bolt, clevis bracket to cross member 35 ft lb
Bolt, clevis bracket to rear support 50 ft lb
Bolt, drive plate to crankshaft 55 ft lb
Plug, front band apply arm shaft 13 ft lb
Locknut, front band adj. 25 ft lb
Bolt, fluid pan 120 in lb

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Apply Chart & Gear Ratios

Clutch Apply Chart

1st Rear clutch, OD direct clutch & Overrunning clutch
2nd 2nd band, rear clutch, OD direct clutch & Overrunning clutch
3rd Front clutch, rear clutch, OD direct clutch & Overrunning clutch
4th OD clutch, Front clutch, Rear clutch, OD clutch
Reverse Front clutch, reverse band, OD direct clutch & Overrunning clutch

Gear Ratios
Gear Ratio
1ST 2.45:1
2ND 1.45:1
3RD 1.0:1
4TH 0.69:1
Reverse 2.20:1

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Specification Reference

Specifications
Recommended fluid Mopar ATF +4
Planetary end play .006-.048 in.
Input shaft end play .034-.084 in.
Clutch pack clearance/Front = .070-.129
Clutch pack clearance/Rear = .016-.036
Overdrive clearance = .090-.110
Front clutch 5 discs
Rear clutch 4 discs
Overdrive clutch 5(STD) or 6(Diesel HO) discs
Direct clutch 23 Single Sided discs
Band adjustment from 72 in. lbs.
Front band Back off 1 3/4 turns
Rear band Back off 3 turns

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Technology and Ethics

The Technology IS the Ethic

If the sign on the building or any advertising says,
Transmissions that is declaration to the Universe
that you know how to fix them.
When a product or service is offered, the offer it-
self is a specific claim by the seller that he is ac-
cepting the MORAL and TECHNICAL responsibility
for correct function, for a reasonable length of
time, in exchange for money.

Regardless what you may call your repair, the job

is in your shop to have the complaints and failures
corrected. It doesnt matter how honest you are,
as a person, if you do not fix the causes of the
complaints and failures where is the ethic?

Each transmission develops 3 to 5 complaints and

failures you see over and over again and again.

A service is ethical and deserving to the exact ex-

tent that your service corrects the causes of those
complaints and failures; and does not include a
whole bunch of parts that were not needed.

No more and no less, Gil

Copyright TransGo 2005

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