Diesel Automobile Parts Automobile Parts User Manual

4 February 2005
Dodge Transmission Instructions
1
BD PERFORMANCE TRANSMISSION
Dodge Installation Instructions
1030310
1064152
1064162
1064172
1064182
1064192
1064212
1064232
2WD Transmissions
1991-93
1994-95 (12V)
1996-98 (12V)
1998-99 (24V)
2000-02 (24V)
2003-04 (24V)
2005 (24V)
2006-07 (24V)
518
47RH
47RE
47RE
47RE
48RE
48RE
48RE
1030311
1064154
1064164
1064174
1064184
1064194
1064214
1064234
4WD Transmissions
1991-93
1994-95 (12V)
1996-98 (12V)
1998-99 (24V)
2000-02 (24V)
2003-04 (24V)
2005 (24V)
2006-07 (24V)
518
47RH
47RE
47RE
47RE
48RE
48RE
48RE
* Transmission kits are also available, which include a BD PressureLoc.
Please read the instructions and disclaimer before beginning installation.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
4 February 2005
Dodge Transmission Instructions
2
REMOVAL:
1. Disconnect the negative battery cable(s).
2. Remove the torque converter access cover and inspection plate.
3. Remove the transmission pan, drain the fluid and re-install the pan.
4. Remove the fill tube bracket bolt and pull the tube out of the transmission. Retain the fill
tube seal. On 4WD models, it will also be necessary to remove the bolt attached to the
transfer case vent tube to the converter housing.
5. Rotate the crankshaft with a pry bar from under the vehicle until the converter bolts are
accessible.
6. Mark the drive shaft and pinion yokes for assembly alignment. Disconnect and remove
the drive shaft. On 4WD models, remove both drive shafts.
7. Disconnect the electrical wiring from the park/neutral position switch, transmission
solenoid, and speed sensor.
8. Disconnect the gearshift rod and shifter shaft assembly from the transmission.
9. Disconnect the TV (throttle valve) cable from the transmission bracket.
10. On 4WD models, disconnect the shifter rod from the transfer case shift lever.
11. Raise the transmission slightly by using a service jack to relieve the load on the crossmember and supports.
12. Remove the bolts securing the rear support and cushion to the transmission and crossmember.
13. Disconnect the vacuum lines and remove the steel line from the cross-member and
frame.
14. Remove the bolts attaching the cross-member to the frame. Spread the frame with a PortA-Power to remove the cross-member.
15. On 4WD models, remove the transfer case with a transmission jack or with the aid of a
helper.
16. Disconnect the fluid cooler lines at the transmission.
17. Remove all bell housing bolts.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
4 February 2005
Dodge Transmission Instructions
3
18. Carefully work the transmission and torque converter assembly rearward off the engine
block dowels.
19. Lower the transmission and remove assembly from under the vehicle.
20. Carefully slide the torque converter out of the transmission.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
4 February 2005
Dodge Transmission Instructions
INSTALLATION:
1. Flush the cooler and all cooler lines before installing the transmission.
2. ***NOTE: If new bolts are supplied with the converter, be sure to remove the bolts before
installing the transmission.
3. Lubricate the converter drive hub and oil pump seal lip with petroleum jelly.
4. Lubricate the converter pilot hub with transmission fluid.
5. Align and install the torque converter into the oil pump.
6. Carefully insert the converter into the oil pump. Rotate the converter back and forth until
it’s fully seated in the pump gears. Two loud “clunks” should be heard to ensure it is
seated properly.
7. Position the transmission on a service jack and secure it with chains.
8. Check the condition of the converter drive plate. If the plate is cracked, distorted or
damaged, it must be replaced before installation can continue. Also be sure the
transmission dowel pins are seated in the engine block and protrude far enough to
hold the transmission in alignment.
9. Raise the transmission and align the torque converter with the drive plate, and the bell
housing with the engine block.
10. Move the transmission forward. Raise, lower or tilt the transmission to align the bell
housing with the engine block dowels.
11. Carefully work the transmission forward and over the engine block dowels until the
converter hub is seated in the crankshaft.
12. Install the bolts attaching the bell housing to the engine.
13. Tighten the bolts and check the torque converter rotation.
14. Install the rear support. Lower the transmission onto the cross-member and install the
bolts attaching the transmission mount to the cross-member.
15. Reconnect the vacuum lines and re-install the steel line to the cross-member and frame.
16. Reconnect the shift linkages.
17. Connect the gearshift and throttle cable to the transmission.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
4
4 February 2005
Dodge Transmission Instructions
18. Connect the electrical wires to the park/neutral position switch and transmission
solenoid(s). Be sure the transmission harnesses are properly routed.
CAUTION: It is essential that correct length bolts be used to attach the converter to the
drive plate. Bolts that are too long will damage the clutch surface inside the converter.
19. Install the torque converter to drive plate bolts using Loctite. On models with a 12.2”
converter, tighten bolts to 47 Nm (35 ft. lbs.).
20. Install the torque converter housing access covers.
21. Install the cooler line bracket.
22. Connect the cooler lines to the transmission.
23. Install the transmission fill tube. Install a new seal on the tube before installation.
24. Align and connect the drive shaft.
25. Adjust the gearshift linkage and throttle valve cable if necessary.
26. Lower the vehicle.
27. Reconnect the negative ground cable(s) to your battery(s).
28. Fill the transmission with ATF+4, Type 7176 fluid.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
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4 February 2005
Dodge Transmission Instructions
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KICK-DOWN CABLE ADJUSTMENT
Kick-down cable adjustment is one of the most critical adjustments that affect the operation
of the transmission.
The BD Performance Valve Body is a performance product and not stock, therefore the
factory specifications for this adjustment are used only as a guide.
Your drivability and performance demands will determine your shift
points and pressure adjustments.
Kick down cable adjustments are for Full Throttle shift points & passing gear only.
Throttle shift points should be adjusted on the valve body throttle valve stop.
12 VALVE ADJUSTMENTS
nd
Light
rd
On trucks equipped with the 12-valve 5.9 6BTA, full throttle shift between 2 and 3 should
occur between 2400 – 2500RPM (OEM) with the transmission at operating temperature.
IMPORTANT - Locate the kick-down cable and MARK THE CABLE at the original setting
before any adjustments are made.
MARK
HERE
NOTE: Disconnecting the cable from the support bracket and the throttle lever is a difficult
task; it may be easier to adjust without removing cable.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
4 February 2005
Dodge Transmission Instructions
24 VALVE ADJUSTMENTS
7
nd
rd
On trucks equipped with Cummins ISB engines, full throttle shift between 2 and 3 should occur
between 2800 – 3000 rpm (OEM) with transmission at operating temp. The kick down cable will
be located underneath the plastic cover as indicated below.
The plastic cover is held in place by 2 plastic Phillips head screws, only light pressure is required
to remove them. Do not lose the screws or washers when you remove them. Remove the cable
from the throttle linkage and support bracket.
**IMPORTANT: MARK THE CABLE at the original setting before any adjustments are made.
Remove the white colored locking clip from the cable.
Press the lock tab (this will take considerable force) to release the locking mechanism.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
4 February 2005
Dodge Transmission Instructions
Adjusting the cable forward, towards the radiator, will
make the transmission shift sooner.
Adjusting the cable rearward, towards the firewall, will
make the transmission shift later.
**CAUTION** DO NOT USE A SCREWDRIVER TO REMOVE CLIP, IF THE CLIP BREAKS
THE CABLE WILL HAVE TO BE REPLACED!
(Adjustment spec - 1/8 inch movement = ~75 rpm)
Install white locking clip and then re-install the cable through the support bracket and then on to
the throttle lever. Install plastic cover when job is complete.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
8
4 February 2005
Dodge Transmission Instructions
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BD Engine Brake, Inc. (BD) warrants to the original purchaser that any parts purchased shall be free from defects in
material and workmanship. BD limits the liability to the repair or replacement, at BD's option, of any warrantable product
returned prepaid with a complete service history and proof of purchase. A valid proof of purchase is a dated bill of sale.
Repaired or replaced product will be returned to the customer freight collect. Accepted warranty units, which have been
replaced, become the sole property of BD.
A Return Material Authorization (RMA) number, obtained in advance from a BD customer service representative, must
accompany product, returned prepaid by the purchaser, for warranty determination. BD will be the final authority on all
warranty decisions.
This parts warranty shall terminate at the end of 12 months or 24,000 miles in service with original user, whichever comes
first. Labor costs incurred by the removal and replacement of a BD Performance Converter while performing warranty
work, will be covered for 12 months at authorized centers with prior approval. Until the product has been approved at the
original installing dealer or at one of our distributors, the consumer should cover these costs.
NOT COVERED UNDER THIS WARRANTY
This warranty shall not apply to any unit that has been improperly stored or installed; or to misapplication, improper
operation conditions, accidents, or neglect, or which has been improperly repaired or altered or otherwise mistreated by
the owner or his agent.
NOTE: The fluid coupling is designed for heavy throttle acceleration and as such the TCC should be UNLOCKED in this
situation. If the TCC is locked up under light acceleration, BD recommends the use of no more than 1 psi of boost for
every 100 rpm of engine speed.
The nature of this product is PERFORMANCE and is designed to perform at above OEM specifications. This product was
designed with this in mind and should NOT be used in RACING and/or HIGH HORSEPOWER applications and will only
be considered for warranty on vehicles with a maximum of 400 REAR WHEEL HORSEPOWER. Using this product on
vehicles with a higher rating will cause premature failure and therefore BD will not consider such claims. BD reserves the
right to void the transmission warranty if a BD torque converter is not used throughout the warranty period of the
transmission.
Except as set forth in our parts outline, BD disclaims any implied warranties of merchantability and fitness for a particular
purpose. BD also disclaims any liability for incidental or consequential damages including but not limited to, repair labor,
rental vehicles, hotel cost or any other inconvenience cost. This warranty is in lieu of all other warranties or guaranties,
either expressed or implied, and shall not extend to any consumer or to any person other than the original purchaser
residing within the boundaries of the continental U.S. or Canada.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com