48RE Converted Valve Body

48RE Converted Valve Body
R E M ANUFAC T UR E D VA LVE BO DIES
Instructions
48RE Converted
Valve Body
Part No.
CHR135
•Converted Valve Body
•Detent Ball
•Manual Valve
.363" dia.
Patent Pending
NOTE: If using in a 46/47RE
application, a triple-plate
converter must be used.
NOTE: A 48RE core must be
returned to your distributor for
proper credit.
1. Assemble supplied Sonnax components onto Sonnax valve body along with the rooster
comb and seal, park rod, TV lever, flat washer and E-clip from original valve body.
2. Install Sonnax valve body onto case.
Figure 1
Throttle cable
Throttle
cable return
spring
Throttle
lever
3. Starting at the four bolts around the governor solenoid, torque valve body-to-case bolts to
100 in/lb (12 Nm).
4. Verify the park position locks the output shaft
before installing pan.
Throttle Adjustments
NOTE: Sonnax valve body works on TV cablecontrolled or TTVA type (motor-controlled).
Press button
in to release
cable.
Throttle cable
connection to
throttle linkage
Earlier upshifts:
Push cable
housing in
TV Cable-Controlled:
Throttle lever (Figure 1) and throttle valve
should move simultaneously when throttle pedal
is depressed. Adjust throttle cable (Figure 2) for
desired shifts.
Use white lithium grease on
the ball end of the throttle lever
to prevent cable hang-up.
TTVA Controlled:
The distance between the bracket and the inside
edge of the adjustment bolt head (Figure 3)
should be .905". The TTVA motor will re-calibrate to this setting at every start up.
©2016 Sonnax Industries, Inc.
866-243-8829 • 856-848-0908 • F: 856-848-1080 • www.sonnax.com
Figure 2
Later upshifts:
Pull cable out
Figure 3
.905"
CHR135-IN 04-20-16
Page 1
R E M ANUFAC T UR E D VA LVE BO DIES
Instructions
CONVERTED 48RE VALVE BODY CHR135
48RE Transmission Throttle Valve Actuator Codes
In 2005 Dodge began using a Transmission Throttle Valve Actuator (TTVA) on 48RE diesel 2500 and 3500
Ram trucks, instead of the T.V. cable. The TTVA is mounted to the case above the throttle valve shaft. It has a
DC motor that is controlled by the ECM, and two potentiometers as inputs to the ECM. The bottom of the
TTVA shaft has a “D”-shaped opening that fits onto the throttle shaft to control transmission throttle pressure.
There are no adjustments for the TTVA. The TTVA will need to be initialized when replaced or removed and
reinstalled. To initialize, turn the ignition to the “on” position for 30 seconds. This is the amount of time the
ECM needs to perform the internal calibration procedures and find the current “zero” position. Every time the
ignition is cycled on, the ECM performs the internal calibration procedure to find the current “zero” position.
During the calibration procedure, the ECM is looking for at least 48 degrees of movement from minimum to
maximum span and a minimum range. Both of these parameters can be affected by the throttle shaft adjustment
bolt on the pressure regulator spring retaining bracket. The distance between the bracket and the inside edge of
the adjustment bolt head should be .905". Some of the cable-activated throttle valve brackets have as little as .820"
between the bracket and the inside of the adjustment bolt head. Using the cable-type bracket without changing the
setting on the adjustment screw can set P1751 and/or P1752.
Figure 4
NOTE: Sonnax remanufactured valve body CHR135 is already adjusted
correctly and ready to use. Using the OE throttle pressure adjustment
gauge will NOT result in proper setting due to internal valve specifications.
Transmission Throttle Valve Actuator Code List
• P1749 – Transmission Throttle Valve Position Sensor Circuit Low.
• P1750 – Transmission Throttle Valve Position Sensor Circuit High.
• P1751 – Transmission Throttle Valve Position Minimum Range Perf.
• P1752 – Transmission Throttle Valve Span Performance.
• P1753 – Transmission Throttle Valve Mechanical Performance.
• P1754 – Transmission Throttle Valve Actuator Stuck.
• P1755 – Transmission Throttle Valve Control Circuit.
Figure 6
Figure 5
48RE Core Identification
The following chart is for 48RE core identification. A 48RE core must be
returned to your distributor for proper credit.
Upper Valve Body
(PR) Casting #
Channel
Casting #
Lock-Up
Casting #
Number Stamped
in Main Plate
4617003
52854129AA
52118502AB
27
Front Clutch
(Direct)
NOTE: See Figures 4, 5 and 6 for proper core identification numbers
and locations.
Tech Tip
This family of transmissions commonly exhibits the symptom of late
shifting into 3rd gear. Recommend air-testing front clutch circuit to
verify there are no leaks before replacing valve body for this concern
(Figure 7). Historically, many technicians have replaced valve bodies
unnecessarily for this issue when in fact there was a leak somewhere
in the front clutch circuit that was responsible.
Rear Clutch
(Forward)
Figure 7
Front
Servo
Release
Front Servo
Apply
Rear Servo
Apply
Overdrive
Clutch
Apply
Overdrive Clutch Pre-Fill
©2016 Sonnax Industries, Inc.
866-243-8829 • 856-848-0908 • F: 856-848-1080 • www.sonnax.com
CHR135-IN 04-20-16
Page 2
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