Transmission R&R - Automatic

Complete removal and reinstallation of the 68RFE automatic transmission from a 2007 Ram 3500 with 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Torque converter bolts (if reused bolts are damaged) × 4 — Use OEM specification
• Transmission cooler line O-rings × 2 — Use OEM specification
• Exhaust gaskets (if disturbed) × 1 — Use OEM specification
• Transfer case gasket/seal (if applicable) × 1 — Use OEM specification

Fluids

• ATF+4 — 20 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect both battery terminals, negative first
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove skid plates if equipped
5. Place drain pan under transmission and drain transmission fluid from pan
6. Mark driveshafts for reinstallation alignment with paint or punch marks
7. Remove rear driveshaft and front driveshaft, secure out of work area
8. Support exhaust system and remove crossover pipe or sections interfering with transmission removal
9. Remove transmission crossmember heat shield if equipped

Procedure

1. 1

   Disconnect electrical and mechanical connections
   Disconnect transmission wiring harness connector from transmission. Disconnect shift linkage at transmission lever. Remove any clips or brackets securing wiring to transmission. Disconnect vehicle speed sensor connectors. Disconnect transmission temperature sensor if accessible. Take photos of routing for reference during reinstallation.
2. 2

   Remove transfer case
   Support transfer case with transmission jack or separate jack. Remove transfer case-to-transmission mounting bolts (typically 6 bolts). Carefully slide transfer case rearward off transmission output shaft. Lower transfer case and remove from under vehicle. Inspect transfer case input shaft seal and replace if needed.
3. 3

   Disconnect transmission cooler lines
   Using line wrenches, disconnect transmission cooler lines at transmission fittings. Have drain pan positioned as residual fluid will drain. Remove and discard O-rings from fittings. Cap or plug cooler lines and transmission ports to prevent contamination. Remove any brackets securing cooler lines to transmission.
4. 4

   Remove starter motor
   Disconnect starter electrical connections and note orientation. Remove starter mounting bolts and carefully remove starter motor from bellhousing. This provides access to lower bellhousing bolts and torque converter. Set starter aside in safe location.
5. 5

   Access and mark torque converter
   Through starter opening, rotate crankshaft using breaker bar on front crankshaft bolt to access torque converter bolts. Mark torque converter position relative to flexplate with paint marker for balance reference. Remove all torque converter-to-flexplate bolts (verify count against factory manual, typically 6 on Cummins applications). Push torque converter back slightly toward transmission to disengage from flexplate.
6. 6

   Support transmission
   Position heavy-duty transmission jack under transmission pan. Use wood block or transmission adapter on jack to distribute weight. Secure transmission to jack with safety chain or strap. Raise jack slightly to take weight off crossmember but do not lift transmission.
7. 7

   Remove transmission crossmember
   Remove transmission mount-to-crossmember bolts/nuts. Remove crossmember-to-frame bolts on both sides. Carefully lower and remove crossmember from vehicle. Inspect transmission mount rubber for deterioration and replace if needed during reinstallation.
8. 8

   Remove bellhousing-to-engine bolts
   Locate and remove all bellhousing-to-engine block bolts. There are typically 6-8 bolts of varying lengths around perimeter of bellhousing. Note bolt locations and lengths for proper reinstallation. Upper bolts may require long extensions or flex-head ratchets. Remove any inspection covers or dust shields from bellhousing.
9. 9

   Separate and remove transmission
   With all fasteners removed, carefully slide transmission rearward away from engine. Transmission must move straight back to disengage input shaft from torque converter. Use pry bars at bellhousing flange if needed, never pry on transmission pan. Keep torque converter pushed back and secure it to transmission with wire or strap so it doesn't slide off input shaft. Once clear of engine, carefully lower transmission jack and roll transmission out from under vehicle.
10. 10

    Inspect and prepare for installation
    Inspect flexplate for cracks or damaged ring gear teeth. Check crankshaft pilot bearing/bushing in crankshaft for wear. Inspect torque converter hub for damage or excessive wear. Clean bellhousing mating surfaces on engine and transmission. Ensure torque converter is fully seated in transmission pump (should be recessed approximately 1 inch from bellhousing face). Turn input shaft while pushing converter forward to fully engage all splines.
11. 11

    Install transmission to engine
    Apply thin coat of high-temp grease to torque converter hub and pilot. Ensure torque converter is still fully seated in transmission. Carefully raise transmission into position using transmission jack. Align transmission with engine, ensuring dowel pins engage properly. Slide transmission forward until bellhousing contacts engine block. Transmission should slide on smoothly; if resistance occurs, check alignment and torque converter position. Never draw transmission to engine with bolts.
12. 12

    Install bellhousing bolts and torque converter
    Install all bellhousing-to-engine bolts in correct locations. Tighten bolts gradually and evenly in a crisscross pattern around the perimeter to seat the transmission squarely against the block. Rotate crankshaft to align torque converter bolt holes with flexplate. Install torque converter-to-flexplate bolts, aligning marks made during removal. Tighten converter bolts evenly and alternately (crisscross), then torque to factory specification. Rotate crankshaft through complete revolution to verify no binding or interference.
13. 13

    Reinstall crossmember and mount
    Raise transmission slightly with jack if needed for clearance. Position crossmember into frame mounts and install frame bolts finger-tight. Install transmission mount-to-crossmember fasteners. Align crossmember for equal spacing on both sides, then torque all fasteners. Remove transmission jack.
14. 14

    Reconnect all components
    Install starter motor and electrical connections. Install new O-rings on transmission cooler line fittings, lubricate with ATF, and connect cooler lines. Clean transfer case mating surface and install new gasket if used. Raise transfer case into position, align with transmission output shaft, and install mounting bolts. Connect all electrical connectors using reference photos. Reconnect shift linkage and adjust if necessary. Install driveshafts aligning reference marks made during removal.
15. 15

    Fill transmission and complete installation
    Install new transmission filter and pan gasket. Reinstall transmission pan. Reinstall exhaust components with new gaskets if disturbed. Reinstall skid plates. Fill transmission with approximately 8-10 quarts ATF+4 initially. Reconnect battery terminals, positive first then negative. Start engine and check for leaks. With engine idling and parking brake applied, shift through all gear ranges pausing in each position. Check fluid level with engine running in Park at operating temperature. Add fluid as needed to reach proper level on dipstick. Total capacity is approximately 16-17 quarts (verify against factory service manual).s.

Reassembly

1. Torque all fasteners to specification if torque values become available
2. Ensure torque converter is fully seated before mating transmission to engine (approximately 1 inch recessed)
3. Align balance marks on torque converter and flexplate during installation
4. Replace all O-rings and gaskets with new components
5. Verify proper transmission fluid level with engine at operating temperature in Park position

Verification

• Start engine and verify no fluid leaks from pan, cooler lines, or mating surfaces
• With parking brake applied, verify transmission engages in all gear ranges (P-R-N-D-3-2-1)
• Verify no unusual noises from transmission or torque converter area
• Test drive vehicle and verify smooth shifting in all gears under light and moderate throttle
• Check for proper speedometer/odometer operation confirming vehicle speed sensor connection
• Verify 4WD engagement if transfer case was disturbed
• Recheck transmission fluid level after test drive with transmission at operating temperature
• Inspect under vehicle for any fluid leaks after test drive

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