545RFE Master Rebuild Kit 2005, new and ready to install. Fits the 545RFE. Ships fast from the USA.
If your 2005 Ram 1500, Durango or Grand Cherokee has the five-speed 545RFE and it now flares on the 2-3 shift, slips in 4th or 5th on the highway, or drops into limp mode, the clutch packs are usually past saving. This 2005 master rebuild kit is the box of soft parts for a complete teardown. The product photo shows full friction and steel packs, a pan filter, a cylindrical filter that appears to be the spin-on cooler-return filter, the case and pan gasket set, lip seals, O-rings and sealing rings. Compare that photo with your own teardown list before you start.
The 545RFE has no bands. It shifts entirely by trading one clutch for another: three input clutches (underdrive, overdrive and reverse) in the input clutch assembly and three holding clutches (2C, 4C and low/reverse) in the case. The controller times every shift by watching how long each pack takes to fill, so a worn friction or a leaking seal shows up as a flare, a bind or a ratio code. A master kit renews all six packs and every seal in one job instead of patching the one that failed first.
What makes the five-speed different from its four-speed twin is programming, not hardware. The 545RFE adds a 5th gear (0.67:1) that uses the overdrive clutch plus the 2C clutch, and a 2nd prime ratio (1.67:1) used on downshifts. That puts more work on the overdrive pack than in a 45RFE, which is why 545RFE units so often come apart with the OD frictions burned while the rest look serviceable.
Check the fluid hot and pull the pan. Heavy clutch material means the packs are done, but the overdrive clutch rarely burns on its own: worn solenoid switch valve bores and a bad OD dribbler in the stator support are common root causes. Our overdrive clutch failure guide shows how to read the ratio codes against the apply chart, and the valve body testing guide covers the P0871 switch valve problem that will burn new frictions if it is left in place.
This kit is listed for the 545RFE in 2005. The same kit is sold for the 2005 45RFE because the two units share clutch packs, seals and gaskets. Chrysler used both transmissions across the 2005 Ram, Durango, Dakota and Grand Cherokee lineup depending on engine, so read the build tag on the case rather than going by the badge, and match the pan shape and filter style to the photo. If you are unsure, send your year and VIN before it ships. Earlier and later years are on the 45RFE and 545RFE collection page.
For what the rest of the job costs, see the 45RFE rebuild cost breakdown.
| Fits | 545RFE 2005 |
| Part type | Master Rebuild Kit |
| Condition | New |
| Brand | OEM |
| Ships | From the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
Yes. The 45RFE and 545RFE share their clutch packs, seals and gaskets; the five-speed is a programming change. The same kit is listed for both 2005 units. Confirm with the build tag on the case.
Mopar ATF+4 only. Chrysler lists an overhaul fill of 14.0 to 16.0 liters depending on cooler and line size, so have about 16 quarts on hand and set the final level hot on the dipstick.
3rd, 4th and 5th all use the overdrive clutch, so a slip only in those gears points to the OD pack or its feed circuit. Check the solenoid switch valve bore and the OD dribbler before reusing the valve body.
Yes. The controller tracks clutch volume for each pack, so reset the adaptives and run a quick learn after the rebuild, or it will try to shift like the worn unit did.
Inspect and replace as needed the input clutch assembly, pump bushing, 4C retaining ring and speed sensors, and have the torque converter serviced or replaced, since it holds debris from the old clutches.
