Disclaimer: Long read.


Hello all!

I have a 2004 Ram 1500 SLT QCSB 5.7 4x2 545RFE. 158000 miles. Completely stock save for a muffler.

December 24th I was driving home from work on the interstate at 70-75mph. I exited from the highway and immediately hit stop and go traffic. After a grocery store stop (15 minutes), I resume the drive home.

The truck at this time, now only has one forward gear (2nd). Reverse is fine. Started from stop in 2nd and when it was time to shift to 3rd, it was another neutral. I get home and park the truck out of frustration.

Some time later, I scan the codes hoping for an easy fix. (P0733. 3rd gear ratio mismatch) I drop the pan and the valve body to find the accumulator retainer plate was bent and pulled a few screws out of their holes damaging the threads. Two of the five accumulator pistons were jammed between the bent plate and VB.

I order new accumulator pistons and a stronger plate from Sonnax (also, ATF+4, filter kit, VB separator plate, black RTV and brake parts cleaner.

The accumulator plate required three new holes drilled and tapped. So, I tear down the VB and I loosen the wrong bolts for the solenoid pack and a bunch of plungers and springs fell out. (Panic) I piece it back together the best I can and take it off the VB the proper way. Then, disassemble the VB all the way down to drill the new holes. Afterward, I spray the fire out of the pieces with brake cleaner to make sure there are no shavings within the passages. Reassemble the VB and reinstall.

The whole time frame between pan down and pan up is about 4 months. (Wait time between parts arriving and finding time to fix this) When I put new ATF in it, it took 9 quarts. (I think the cooler and TC drained a bit) I took it for a drive and I had 1st, 2nd and 3rd but no OD or kickdown. Stopped at a light and 1st left chat also I now have to manually shift into 3rd and manually back to 2nd. I park the truck in frustration and scan codes. (P0987 4C pressure sensor/switch "E" circuit)

I cleaned the 23 pin harness and try again to same issues. I go to a transmission shop to "relearn" the transmission as I read it may be the issue. No change.

I can only assume now the shift solenoid is either bad or I messed it up during disassembly.

Please help.[img]data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7[/img]

 

at that many miles the solenoid pack should be replace regardless. they are prone to fail..
this scanner will give you all your pressures and do the re-learn as well for cheap.
https://braydentechs.com/dodge-jeep-...vel-scan-tool/
this is a great manual for the 545RFE keep in mind the 45RFE and 545RFE are the same exact transmission. with different programing.
https://akppservice.by/assets/files/45RFE.pdf
make sure you torque down all the torx bolts on the valve body to specs. think there are 28 of them . look in Manuel for the inch pounds on the torque.
check the L/R Switch Valve on the value body to. that is a lot of miles of that trans..
a rebuild is do regardelss so buy the solenoid pack you can use it on the rebuild..
and of course make sure the gasket on filter is inserted correctly and not leaking air.. use a socket and put it in first then the filter.
you can always go to this youtube channel and ask tom questions he will replay same day hes great.
https://www.youtube.com/channel/UC5U...M3nkaZVXfoOuzg