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45RFE AUTOMATIC TRANSMISSION

45RFE AUTOMATIC TRANSMISSION

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AUTOMATIC TRANSMISSION - 45RFE
TABLE OF CONTENTS
page
page
AUTOMATIC TRANSMISSION - 45RFE

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 207 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 208 DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 208
DIAGNOSIS AND TESTING -
PRELIMINARY. . . . . . . . . . . . . . . . . . . . . . . 209
DIAGNOSIS AND TESTING - ROAD
TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 209
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST. . . . . . . . . . . . . . . . . . . . 210
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION. . . . 211
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK. . . . . . . . . . . . . . . . 211
STANDARD PROCEDURE - ALUMINUM

THREAD REPAIR. . . . . . . . . . . . . . . . . . . . . 212 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . 214 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . 220 INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . .220 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 221 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 227 SCHEMATICS AND DIAGRAMS

HYDRAULIC SCHEMATICS. . . . . . . . . . . . . 231
SPECIFICATIONS
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 250
SPECIAL TOOLS
RFE TRANSMISSION
. . . . . . . . . . . . . . . . .251
4C RETAINER/BULKHEAD
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . 254
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 254
ADAPTER HOUSING SEAL
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 255
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 256 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 256 DIAGNOSIS AND TESTING - BRAKE

TRANSMISSION SHIFT INTERLOCK
SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 256
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL. . . . . . . . . . . . . 256
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID. . . . . . . . . . . . . . . . . . . . . . . 256
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION. . . . . . . . . . . . . . . . . . . . 256
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT. . . . . . . . . . . . . . . 257
STANDARD PROCEDURE - TRANSMISSION
FILL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT

CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 260 ADJUSTMENTS - GEARSHIFT CABLE. . . . . . 261

HOLDING CLUTCHES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 262
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 263
INPUT CLUTCH ASSEMBLY

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 264 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 264 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . 266 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 268

INPUT SPEED SENSOR

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 273 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 273 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 274

LINE PRESSURE (LP) SENSOR

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 274 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 274 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 274

LOW/REVERSE CLUTCH

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . 275 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . 276 INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . .276
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 276
OIL PUMP

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 277 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 277 STANDARD PROCEDURE - OIL PUMP

VOLUME CHECK. . . . . . . . . . . . . . . . . . . . . 278 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . 279 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . 280 INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . .280
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 281
OIL PUMP FRONT SEAL
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 282
21 - 206
AUTOMATIC TRANSMISSION - 45RFE
KJ
OUTPUT SPEED SENSOR

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 282 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 282 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 282

OVERDRIVE SWITCH
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 283
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 283
PARK - INTERLOCK CABLE

REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 283 ADJUSTMENTS - PARK-INTERLOCK CABLE . 284

PISTONS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 285
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 285
PLANETARY GEARTRAIN

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 287 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 287 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . 288 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . 288 INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . .288
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 289
SHIFT MECHANISM

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 290 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 290 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 291

SOLENOID SWITCH VALVE
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 291
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 291
SOLENOIDS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 291
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 292
TORQUE CONVERTER

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 292 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 296 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 297

TRANSMISSION CONTROL RELAY
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 298
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 298
TRANSMISSION RANGE SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 298
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 298
TRANSMISSION SOLENOID/TRS ASSEMBLY

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 299 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 299 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 300

TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 300
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 300
VALVE BODY

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 301 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 301 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . 303 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . 305 INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . .306 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 307 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 307

AUTOMATIC TRANSMISSION -
45RFE
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:

\u2022Three multiple disc input clutches
\u2022Three multiple disc holding clutches
\u2022Five hydraulic accumulators
\u2022Three planetary gear sets
\u2022Dual Stage Hydraulic oil pump
\u2022Valve body
\u2022Solenoid pack

The TCM is the \u201cheart\u201d or \u201cbrain\u201d 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.).

KJ
AUTOMATIC TRANSMISSION - 45RFE 21 - 207
TRANSMISSION IDENTIFICATION

Transmission identification numbers are stamped on the left side of the case just above the oil pan sealing 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

OPERATI ON

The 45RFE offers full electronic control of all auto- matic up and downshifts, and features real-time adap- tive closed-loop shift and pressure control. Electronic shift and torque converter clutch controls help protect the transmission from damage due to high tempera- tures, which can occur under severe operating condi- tions. By altering shift schedules, line pressure, and converter clutch control, these controls reduce heat gen- eration 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 pressure greatly

exceeds that which is needed to keep the clutches applied. The 45RFE pump-pressure control system mon- itors input torque and adjusts the pump pressure accordingly. The primary stage of the pump works con- tinuously; the second stage is bypassed when demand is low. The control system also monitors input and output speed and, if incipient clutch slip is observed, the pres- sure control solenoid duty cycle is varied, increasing pressure in proportion to demand.

A high-travel torque converter damper assembly allows 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 \u201climp-in\u201d 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\u2019s, etc.) which is helpful in proper diagnosis and repair. This information can be viewed with the DRB\ue002 scan tool.

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION

CAUTION: Before attempting any repair on a RFE automatic transmission, check for Diagnostic Trou- ble Codes with the DRB\ue001 scan tool.

Transmission malfunctions may be caused by these
general conditions:

\u2022Poor engine performance
\u2022Improper adjustments
\u2022Hydraulic malfunctions

Fig. 1 Transmission Part And Serial Number
Location
1 - IDENTIFICATION NUMBERS (STAMPED)
21 - 208
AUTOMATIC TRANSMISSION - 45RFE
KJ
AUTOMATIC TRANSMISSION - 45RFE (Continued)

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