Torque Converter

This procedure covers removal and replacement of the torque converter on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine and 4WD, requiring transmission removal to access the converter.

Warnings

Tools required

Parts

• Torque converter × 1 — Must match transmission model (47RE or 48RE)
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Drain plug washer × 1 — Use OEM specification
• Torque converter bolts × 4 — Use new fasteners
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent

Fluids

• Mopar ATF+4 — 14 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect both battery cables, negative first
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove skid plates and crossmember guards if equipped
5. Place drain pan under transmission
6. Allow transmission to cool completely if vehicle was recently operated

Procedure

1. 1

   Drain transmission fluid
   Remove transmission drain plug from pan and allow fluid to drain completely. Once drained, reinstall drain plug with new washer. Remove transmission fill plug to allow air circulation during drain.
   Torque spec

   Drain Plug34 Nm (25 lb-ft)

   Fill Plug34 Nm (25 lb-ft)
2. 2

   Remove transfer case and crossmember
   Drain transfer case fluid. Mark front and rear driveshaft positions relative to yokes. Remove front and rear driveshafts. Disconnect transfer case shift linkage and wiring. Support transfer case with jack. Remove transfer case mounting bolts and lower transfer case from vehicle. Remove transmission crossmember mounting bolts and remove crossmember.
3. 3

   Disconnect transmission components
   Disconnect transmission cooler lines at transmission (have rags ready for fluid spillage). Disconnect electrical connectors for speed sensors, solenoid pack, and neutral safety switch. Disconnect shift linkage at transmission lever. Remove throttle valve cable from transmission if equipped. Cap all open lines to prevent contamination.
   ⚠Transmission cooler lines may contain residual pressurized fluid even after draining pan.
4. 4

   Access torque converter bolts
   Remove transmission bellhousing inspection cover at bottom of bellhousing. Rotate engine crankshaft using breaker bar on crankshaft bolt to expose each torque converter bolt through access opening. Mark flexplate and torque converter position for reassembly reference. There are typically 3 or 4 bolts (verify count for your specific flexplate) spaced evenly around the flexplate. Rotate crankshaft to access each bolt. Remove all torque converter bolts while preventing engine rotation.
   ℹ️There are typically 4 bolts spaced 90 degrees apart. Rotate crankshaft to access each bolt.
5. 5

   Support and remove transmission
   Position transmission jack securely under transmission oil pan with wood block for load distribution. Apply slight upward pressure on jack. Remove bellhousing-to-engine block mounting bolts (typically 6 bolts). Carefully slide transmission straight back away from engine, ensuring torque converter stays engaged in transmission pump. Once torque converter clears flexplate, hold converter in place with large C-clamp or wire to prevent it from falling out. Lower transmission from vehicle.
   ⚠️Do not allow transmission to hang on input shaft or damage to clutch hub and pump seal will occur.
   ⚠️Torque converter weighs 30-40 lbs and will slide out once transmission is tilted. Secure it before lowering transmission.
6. 6

   Remove old torque converter
   With transmission on workbench or secure surface with front facing up, remove C-clamp or securing device. Pull torque converter straight out of transmission. Converter is held only by engagement with pump and input shaft. Inspect flexplate teeth through bellhousing opening for wear or damage.
7. 7

   Inspect and clean transmission mounting surface
   Inspect transmission pump seal for damage or leakage. Clean bellhousing mating surface with wire brush. Check that input shaft and pump drive splines are not damaged. Measure flexplate runout if flexplate damage is suspected (should be less than 0.020 inches).
   ℹ️If pump seal shows signs of leakage or is damaged, front pump seal should be replaced before installing new converter.
8. 8

   Prepare and install new torque converter
   Pour approximately 1 quart of fresh Mopar ATF+4 into new torque converter through hub (ATF+4 supersedes earlier ATF+3 for these transmissions). Rotate converter to distribute fluid and coat internal components. Align converter hub with transmission pump and carefully slide converter into transmission. Push converter fully in while rotating slightly to engage pump drive slots, then engage input shaft splines. Converter should drop in two distinct stages as it engages pump then input shaft. Verify converter is fully seated by measuring from bellhousing mounting face to converter ear - should be approximately 1/2 inch or more of clearance.
   ⚠️Converter MUST be fully seated before transmission installation or pump will be destroyed on startup. Verify proper seating depth.
9. 9

   Install transmission to engine
   Secure torque converter to transmission with C-clamp or safety wire. Apply thin coat of high-temp grease to input shaft and converter hub pilot. Raise transmission into position using transmission jack. Align converter hub with crankshaft pilot. Align transmission with engine and carefully slide transmission forward, ensuring converter remains fully engaged. Install all bellhousing mounting bolts and tighten evenly. Remove converter securing device.
   ⚠Transmission should slide forward with minimal resistance. If binding occurs, do not force - lower and check alignment.
10. 10

    Install torque converter bolts
    Rotate crankshaft to align torque converter bolt holes with flexplate holes using marks made during disassembly. Install new torque converter bolts (do not apply thread locker unless specified by factory procedure). Install bolts through access opening and tighten evenly in a star pattern. Rotate crankshaft to access each bolt location. Install inspection cover.
    ℹ️Tighten converter bolts in multiple passes to ensure even loading and prevent flexplate distortion.
    Torque spec

    Torque Converter Bolts50 Nm (37 lb-ft)
11. 11

    Reinstall crossmember and transfer case
    Install transmission crossmember and mounting bolts. Install transfer case to transmission, aligning marks and splines. Install transfer case mounting bolts. Reconnect transfer case shift linkage and electrical connections. Install front and rear driveshafts, aligning marks made during removal.
12. 12

    Reconnect transmission components
    Reconnect transmission cooler lines using new O-rings if applicable. Reconnect all electrical connectors ensuring proper engagement. Reconnect shift linkage and adjust if necessary. Reconnect throttle valve cable if equipped and adjust per factory specification.
13. 13

    Fill transmission and transfer case
    Fill transfer case with approximately 2 quarts of Mopar ATF+4 through fill plug opening (verify exact capacity for your specific transfer case model). Install fill plug to specification. Fill transmission with approximately 14-15 quarts of Mopar ATF+4 through dipstick tube as an initial fill, then adjust to level (total dry capacity is roughly 17-19 quarts with converter). Start engine and allow to idle in Park. Check for leaks at all connections. With engine running and at operating temperature, shift through all gear ranges, pausing 2-3 seconds in each position. Return to Park and check fluid level on dipstick. Add fluid as needed to bring to proper level.
    ⚠Do not overfill transmission. Overfilling can cause fluid aeration and transmission damage.
    Torque spec

    Fill Plug34 Nm (25 lb-ft)
14. 14

    Final inspection and road test
    With engine at idle in Park, verify no leaks from transmission pan, cooler lines, converter bolts area, or pump seal. Lower vehicle and reconnect battery cables (positive first). Test drive vehicle through all gears verifying smooth shifts and proper operation. Recheck fluid level after test drive with transmission at operating temperature. Install skid plates if equipped.

Reassembly

1. Torque all fasteners to specified values in the order listed
2. Ensure all electrical connectors are fully seated and locked
3. Verify driveshafts are installed with original phasing marks aligned
4. Double-check transmission fluid level with engine at operating temperature

Verification

• Start engine and verify transmission engages properly in all gear ranges
• Check for fluid leaks at all connection points with engine running
• Verify no abnormal noises from torque converter or transmission during operation
• Test drive vehicle and confirm smooth shifting under various loads
• Verify transmission fluid level is correct on dipstick with engine at operating temperature in Park
• Recheck fluid level after 50-100 miles of driving and top off if necessary

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