Transmission Rebuild - Automatic

Complete removal, disassembly, inspection, rebuild, and reinstallation of the 68RFE automatic transmission in a 2007 Ram 3500 with 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• 68RFE master rebuild kit × 1 — Use OEM or quality aftermarket kit
• Torque converter (if damaged or high mileage) × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter kit × 1 — Use OEM specification
• Output shaft seal × 1 — Use OEM specification
• Input shaft seal × 1 — Use OEM specification
• Transfer case input seal × 1 — Use OEM specification
• Transmission to engine mounting bolts × 8 — Use OEM specification
• Flexplate to torque converter bolts × 4 — Use OEM specification
• Driveshaft hardware × 1 — Use OEM specification
• Assembly lube × 1 — Petroleum-based transmission assembly lube
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent
• RTV silicone gasket maker × 1 — Use OEM or Permatex Ultra Gray

Fluids

• ATF+4 — 20 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Disconnect both battery cables (negative first, then positive) to prevent electrical shorts
3. Raise vehicle on lift or jack stands rated for vehicle weight, ensuring stability
4. Remove skid plates and belly pans to access transmission and transfer case
5. Place large drain pans under transmission and transfer case
6. Remove both front and rear driveshafts, marking yokes for reinstallation alignment
7. Label and photograph all electrical connectors, shift linkages, and vacuum lines before disconnecting
8. Drain transmission fluid from pan and torque converter drain plug if equipped
9. Drain transfer case fluid completely
10. Support engine using support fixture or overhead hoist with load leveler
11. Have transmission rebuild stand, clean workspace, and all rebuild tools prepared before removal

Procedure

1. 1

   Remove exhaust and crossmember components
   Remove exhaust crossover pipe and downpipe sections that interfere with transmission removal. Remove transmission crossmember mounting bolts and carefully lower crossmember while supporting transmission with jack. Remove transmission mount from crossmember.
2. 2

   Disconnect transmission electrical and mechanical connections
   Disconnect transmission wiring harness connectors including solenoid pack connector, speed sensors, and temperature sensor. Disconnect shift cable from lever and bracket. Remove dipstick tube bolt and pull tube from transmission. Disconnect cooler lines at transmission using flare nut wrenches to avoid rounding fittings. Cap all openings immediately.
3. 3

   Remove transfer case from transmission
   Support transfer case with separate transmission jack. Remove transfer case to transmission mounting bolts (verify exact count against factory service manual). Carefully slide transfer case rearward off transmission output shaft. Lower transfer case and set aside. Remove transfer case adapter housing if it remains on transmission.
4. 4

   Remove torque converter access cover and converter bolts
   Remove dust cover from bellhousing bottom. Rotate crankshaft using breaker bar on front damper bolt to access each flexplate to torque converter bolt through access opening. Remove all four torque converter mounting bolts. Mark flexplate and converter orientation. Push torque converter back into bellhousing to disengage from flexplate studs.
5. 5

   Remove transmission from engine
   Position transmission jack securely under transmission pan with safety chains. Remove all bellhousing to engine block mounting bolts (verify exact count against factory service manual for the Cummins bellhousing pattern). Verify all electrical connections, cooler lines, and mechanical linkages are disconnected. Carefully slide transmission straight back from engine, ensuring torque converter remains fully seated in transmission. Once input shaft clears bellhousing, carefully lower transmission and roll clear of vehicle. Keep transmission level to prevent torque converter from sliding out.
6. 6

   Mount transmission and perform external disassembly
   Mount transmission securely on rebuild stand. Remove valve body pan bolts and carefully lower pan, noting any debris or metal particles. Remove transmission filter. Disconnect all external wiring harnesses and sensors. Remove valve body mounting bolts in proper sequence (verify exact count and sequence against factory service manual) and carefully lower valve body assembly. Keep check balls and springs organized. Remove solenoid pack assembly.
7. 7

   Remove pump assembly and front components
   Remove pump to case bolts (verify exact count against factory service manual). Using slide hammers or careful prying, remove pump assembly from case. Remove front clutch assemblies, thrust washers, and bearings, keeping all components in order. Inspect pump bushing, gears, and sealing surfaces for wear. Remove input shaft and forward clutch drum assembly as a unit.
8. 8

   Disassemble geartrain and clutch packs
   Remove planetary gear sets in proper sequence, noting position of all thrust washers and bearings. Use dial indicator to measure endplay before disassembly. Remove rear clutch assemblies, direct clutch, and overdrive clutch packs. Use spring compressor tool to compress clutch pack springs and remove snap rings. Document clutch pack arrangement, plate count, and wave spring positions. Remove all shafts, sun gears, and carriers.
9. 9

   Remove output components and case internal parts
   Remove output shaft assembly with parking gear and governor support. Remove parking pawl assembly and linkage. Extract all case bushings that show wear using bushing removal tools. Remove all remaining snap rings, thrust bearings, and races. Mark locations of all selective shim locations for reassembly reference.
10. 10

    Clean and inspect all components
    Thoroughly clean all hard parts in solvent or parts washer. Blow dry with compressed air. Inspect all gear teeth for wear, chips, or scoring. Check all bushing surfaces with micrometer against specification. Inspect clutch drums for scoring, heat discoloration, or cracks. Check all steel plates for flatness and wear. Inspect case for cracks, stripped threads, or damaged bearing bores. Replace any components showing wear beyond specification.
11. 11

    Install new bushings and case components
    Install new case bushings using proper drivers, ensuring alignment and full seating. Install new accumulator seals and springs per rebuild kit. Install parking pawl assembly with new spring and shaft. Install governor support with new seal and snap ring. Install output shaft assembly with new bushings and seals, checking for smooth rotation.
12. 12

    Rebuild and install clutch packs
    Soak all new friction plates in ATF+4 for minimum 30 minutes before assembly. Assemble each clutch pack per rebuild kit instructions with correct plate sequence and count. Install new seals on all pistons using assembly lube. Install wave springs and snap rings, ensuring proper snap ring seating. Air check each clutch pack operation before installation in case. Install thrust bearings and races with assembly lube in correct locations per service manual.
13. 13

    Assemble geartrain and measure endplay
    Install planetary assemblies, sun gears, and carriers in proper sequence with all thrust washers properly positioned. Install input shaft and clutch drum assembly. Measure and verify endplay specifications using dial indicator at multiple locations per factory specification. Install proper selective shims to achieve correct endplay. Verify all components rotate freely without binding.
14. 14

    Install pump assembly
    Install new pump seal and O-rings using assembly lube. Check pump gear clearances and backlash per specification. Install pump to case with new gasket or O-ring. Install pump bolts and tighten in crisscross pattern. Verify input shaft rotates freely and has correct endplay after pump installation.
15. 15

    Install valve body and pan
    Position all check balls and springs in correct case locations per diagram. Install new separator plate with gaskets in proper orientation. Carefully position valve body assembly, ensuring all valve bores align correctly. Install and tighten valve body bolts in proper sequence to avoid warping. Install solenoid pack with new O-rings and seals. Install new filter. Clean pan thoroughly, install new gasket, and torque pan bolts in crisscross pattern. Reconnect all external sensors and wiring harnesses.
16. 16

    Reinstall transmission in vehicle
    Install new transfer case adapter seal if equipped. Position transmission on jack and raise into position, keeping perfectly level. Ensure torque converter remains fully seated (verify converter hub depth measurement). Align transmission to engine block and bellhousing dowels. Slide transmission forward carefully until bellhousing contacts engine block. Install all bellhousing to block bolts hand tight, then torque in crisscross pattern.
17. 17

    Install torque converter and transfer case
    Rotate torque converter to align with flexplate and pump drive. Verify converter is fully seated with proper depth measurement before installing bolts. Install torque converter to flexplate bolts through access hole, rotating engine as needed. Install torque converter bolts and torque to factory specification (do not apply thread locker unless specified by the factory service manual). Install dust cover. Install new transfer case input seal in adapter. Position transfer case on transmission jack and carefully align splines while sliding onto transmission output shaft. Install transfer case mounting bolts and torque in sequence.
18. 18

    Reconnect all lines, cables, and install crossmember
    Install transmission crossmember and mount, leaving bolts slightly loose. Connect cooler lines with new O-rings, torquing fittings carefully. Reconnect all electrical connectors per labels and photos. Install shift cable and adjust per specification. Install dipstick tube with new O-ring. Install front and rear driveshafts, aligning marks made during removal. Torque all driveshaft hardware. Torque crossmember bolts with transmission weight on mount. Install skid plates and belly pans.
19. 19

    Fill fluids and perform initial startup checks
    Fill transfer case to the fill plug level with ATF+4 (approximately 2 quarts; verify capacity against factory service manual). Add approximately 10-12 quarts ATF+4 to transmission through dipstick tube initially, noting total dry-fill capacity is approximately 17-18 quarts (verify against factory service manual). Reconnect battery cables (positive first, then negative). With engine off and parking brake set, verify transmission shifts through all gear positions. Start engine and immediately check for leaks at pan, cooler lines, and converter area. With engine at idle and transmission in Park, add additional ATF+4 to bring level to cold mark. Check for proper shift cable adjustment and neutral safety switch operation.

Reassembly

1. All internal transmission clearances must meet factory specifications verified with dial indicator and feeler gauges
2. Every clutch pack must be air checked for proper seal operation before final assembly
3. Torque converter must be verified fully seated with minimum three engagement points before bolting transmission to engine
4. Transmission and transfer case fluid levels must be checked with engine at operating temperature and vehicle on level surface
5. All electrical connectors must click firmly into place and be verified for proper pin engagement

Verification

• Start engine and verify transmission engages in all forward and reverse gears smoothly without harsh shifts or slipping
• Check transmission fluid level with engine at operating temperature in Park on level ground, adjust to proper mark on dipstick
• Verify no fluid leaks at pan gasket, pump seal, cooler lines, dipstick tube, or transfer case adapter after test drive
• Perform 15-20 mile test drive including highway speeds, verifying smooth shifts through all gears, proper lockup converter engagement, and no abnormal noises
• Connect scan tool and verify no transmission trouble codes are present and all solenoids respond properly
• Recheck all fluid levels after test drive and verify transmission fluid is clean red color without burnt smell
• Verify proper speedometer operation and 4WD engagement if equipped
• Perform final inspection of all mounting bolts, cooler lines, and crossmember hardware for proper torque

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