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Installation Manual v2.0: Valve Body Kit

1994-2004 Dodge Ram 2500/3500 With TV Cable

Please read all instructions before installation.

Features of the ATS Valve Body:

• Increased transmission lubrication, even in park. • Increased transmission torque capacity. • Lock up capability in all gears, including manual 1st and 2nd gears. • Downshift from 4th to 3rd while maintaining applied lock-up clutch. • Reduce torque converter drain back after sitting for long periods of time. • Enhanced shift quality. • Exhaust brake ready. • Allows towing in overdrive. • Specially designed for use with the ATS Five Star Torque Converter.

Channel Plate Section

1. Carefully flat stone the channel mating surface, as well as the other side of the unit. 2. Blow small particles from channel plate, using compressed air. 3. Place the two provided 0.250” Viton (plastic) check balls where marked with a crosshair.

See Figure 1

FIG. 1

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4. Install the plastic filter into separator plate B, use figure 2 as a guide.

FIG. 2 5. Use 2 tapered punches to align separator plate B to the channel plate. See figure 3-A.

FIG. 3

6. Place the stiffener plate on the separator plate

47-RH uses 2 bolts on the stiffener plate and 3 bolts on the separator plate (Figure 4) 47-RE uses 4 bolts on the stiffener plate and 1 bolt on the separator plate (Figure 5)

FIG. 4 FIG. 5

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7. Torque all screws to 38 INCH-POUNDS. Make sure that cotter pins are free-moving after tightening plate (Figure 3-B shown in step 5 on page 2).

Main Valve Body Section

8. Inspect the valve body very closely for previous modifications. Look at the partition marked with an arrow. If there is a hole that has been drilled through the partition then place the restrictor pin supplied in this kit through the hole. See figure 6.

FIG. 6

If there is no hole drilled through the land skip to this next step. Place the provided restrictor pin through the hole, bend the ends outwards and cut them off (make sure that the ends are short enough that they can’t become lodged into the pressure regulator valve). Use figure 7 as a guide.

FIG. 7

9. Carefully use a flat stone to knock off any high spots that may cause hydraulic cross leaks. Use compressed air to blow small particles from the casting.

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10. Place the valve body in a vice; protect it from the jaws of the vice by using rags. Remove the valve trains (A through D) as shown. Install the valves (described) in the valve body

a. Switch valve and spring. Figure 8-A b. Pressure regulator valve and purple spring (supplied in kit). Figure 8-B c. Throttle valve, green spring, T.V. plunger and sleeve (supplied in kit). Figure 8-C d. Manual valve (supplied in kit). Figure 8-D

FIG. 8

11. Use the stem of the old plunger valve as a gauge, place plunger valve stem between the plate and the bracket. This should place base line pressure at roughly 75 PSI at 1000 RPM. This will be a good starting point. (Figure 9)

FIG. 9 FIG. 9-2

FIG. 9-4FIG. 9-3

(.250"-.280")

.850" for 24V

.760" for 12V

.850" for 24V

.760" for 12V(.250")

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12. Check your minimum TV adjustment, it should measure approximately 0.850” for Dodges equipped with 24 Valve motors and 0.760” for Dodges equipped with 12 Valve motors. This adjustment controls the slow speed up shift. Figure 9-2.

13. Install the spring retainer on the valve body while the main valve body is in the vice. Install the two bolts (marked A & B in Fig. 9) at this time. Do not tighten the bolts at this time. Only install the two bolts enough to hold the retainer in place, in order to secure the springs (figure 9-3).

14. Remove the valve body from the vice and place it on the bench with the channel side facing up. Place the (6) ¼ inch check balls into the cavities and the (1) 11/32 inch check ball as indicated in figure 10.

FIG. 10 15. Place channel plate B assembly on valve body as indicated in picture.

a. On 47-RH and early 47-RE do not use a check ball in plate (Figure 11). b. On Late 47-RE and 2002-2004 48-RE install a 3/16” check ball indicated in

Figure 12.

** Note: If your valve body has the tub indicated with a circle in Figure 12 install the check ball. If it does not have the tub (Figure 11) do not use the check ball.

FIG. 12FIG. 11

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16. Place separator plate A on channel plate and set aside (Fig. 13).

FIG. 13

Lock-up Valve Body Section

17. Remove timing cover plate (Figure 14-A) 18. Remove 3-4 quick fill valve, spring and plug (Figure 14-B) 19. Remove 3-4 timing valve and spring (Figure 14-C)

FIG. 14

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20. Stand lock-up valve body on end, place 3-4 timing valve spring in bore and drop ¼-inch

check ball (Use 5/16-inch check ball on 48-RE models) inside bore of spring, see figure 15. When the check ball, spring & valve are properly assembled, the valve will not travel below the end of the plate. The check ball is used to block the valve towards the plate (Figure 16).

FIG. 15 FIG. 16

21. Place timing valve plate on valve body and torque the three screws to 38-inch pounds of torque (see Figure 14-A on page 6).

22. On the other side of the valve body, remove the 4th accumulator body that is attached by 3 screws.

23. Remove the 3-4 shift valve assembly, converter clutch valve assembly and the converter clutch timing valve assembly. (Figure 17-A & B)

FIG. 17

24. Discard the original converter clutch shift spring, plug, and timing valve spring (Figure

17-A)

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25. Drill two holes approximately .090-inch in diameter through the valve body partitions in the locations marked with yellow arrows and circled in figure 18. Carefully sand the valve body for a flush top.

NOTE: A “#43” drill bit works best. Do not drill the hole much larger than .090-inch as it will not benefit the transmission’s performance.

FIG. 18 26. Reinstall the original 3-4 shift valve and spring into the valve body. (Figure 17-B) 27. Carefully grind a flat on the land indicated by the arrow (Figure 20) on the converter

clutch valve. The land is ground to allow fluid to pass. Grind the land flush with the base valve diameter to allow venting of oil.

FIG. 19

FIG. 20 Close-up of ground

Component in Figure 19-B

28. Install the converter clutch valve into the bore then the new furnished red spring and then

the new furnished lock-up plug. (Figure 19-C) 29. Install the new blue spring furnished in the kit, then the factory converter clutch timing

valve and retainer. (Spring orientation is reversed from factory).

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30. Install the orifice cup plug marked A (supplied) into the accumulator housing. The cup plug must be installed into the bore and recessed about ½ inch below the surface. Be sure the plug is pushed past the hole marked B. (Figure 21)

FIG. 21 31. Install the 4th accumulator housing on the lock-up valve body section. Torque the 3

screws to 38-inch pounds of torque. 32. Install the accumulator piston and yellow spring into the accumulator housing (shown in

Figure 22-A). Place the plate and install the 5 screws on the accumulator housing, tighten the screws to 38-inch pounds of torque (Figure 22-B).

FIG. 22

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Installing Valve Body Sections Together 33. Place lock-up valve body assembly over channel plate section and install the 2 screws as

indicated, these two screws are line-up screws. Snug the two screws down and install the remaining screws into the valve body. Starting from the inside and working your way out. Torque all bolts to 38-inch pounds. (Figure 23)

FIG. 23 34. Install the boost tube on the side of the valve body; this tube connects the main valve

body to the lock-up valve body (Figure 24-A). Remember to install the hold down bracket for the boost tube (Figure 24-B). Tighten the last two screws on the spring retainer (Figure 24-C).

FIG. 24

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35. Bend the locking tabs over to secure the boost tube to the valve body (Figure 25-A).

FIG. 25 36. If your transmission is a 48-RE model, skip this step. Locate the boost valve plate; use a

1/16-inch drill bit to enlarge the hole in the plate, after enlarging the hole install the plate on the valve body (Figure 26).

FIG. 26

37. Install the manual linkage onto the main valve body. Place the spring into the valve body and place the 11/32-inch steel ball on the spring (Figure 27-A). Use a tie wrap to keep the ball and spring in the valve body while installing the manual linkage (Figure 27-B).

FIG. 27

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38. With the ball and spring secured in place by the tie wrap, place the shifter linkage over while lining up the manual linkage with the manual valve (Figure 28-A). Remove tie wrap after linkage is in place.

FIG. 28 39. Install detent seal over detent rod. Be sure to install the seal correctly. Use the picture

provided as a guide. Use a 3/8-inch socket to push the detent seal into the linkage pocket (Figure 29-A).

FIG. 29

40. Install the metal washer and E-clip over the seal to secure it into place. After the seal, washer and clip is installed the linkage and detent rod should rotate freely.

41. Reinstall the solenoids using the gaskets provided. a. 47-RH uses shift solenoid gaskets with screens. b. 47-RE and 48-RE use shift solenoids gasket with screens and governor gasket.

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42. Manual linkage may not go to full manual low range if the 5 bolt retainer plate (Figure

30-A) has been positioned incorrectly. Give special attention to the linkage (Figure 30-B) when rotated to full low range (clockwise), the detent ball should index into the manual linkage fully (Figure 30-C).

FIG. 30 Have Any Questions?

Thank you for purchasing the ATS Valve Body Kit. Please check our website at http://www.atsdiesel.com for technical support and other performance products such as the Five Star™ torque converter, ATS High Performance Transmission along with our full line of power enhancers. Please call or e-mail our Sales or Technical Service Department, 8:00am to 5:30pm Mountain Standard Time, Monday through Friday.

Contact Information

Toll Free: 800-949-6002

Local: 303-431-7973 Fax: 303-431-0135

Website: www.ATSDiesel.com Email: info@ATSDiesel.com