SunCoast Category 5 800HP+ 48RE Transmission Rebuild Kit w/ Flex Plate 03-07 Dodge/Ram 5.9L Cummins

The addition of a billet intermediate servo, billet band anchor and billet band strut address the common know shortcomings of the 48RE transmission. This kit also comes with a new billet blueprinted 4.4 band lever and new thrust washer kit containing selections for setting endplay.

Category 5 rebuild kits also includes SunCoast's larger one-piece billet 27-spline input shaft. The shaft is milled from 300 maraging steel and is then heat treated and stress relieved to handle the additional demands of higher torque and stress loads. The shaft is precision ground to exact tolerances. It also features SunCoast's exclusive 27-spline stator support to accommodate the larger input shaft.

The Category 5 48RE master rebuild kit includes a band upgrade. While some of their other kits include a Raybestos Pro Series carbon fiber flex band, in this kit SunCoast uses a billet rigid band. This band is CNC machined from billet steel and then lined with carbon graphite lining to ensure unmatched performance even by other manufacturers.

For full competition builds, safety is and should always be at the forefront of SunCoast's process. One of the biggest upgrades for this kit is the addition of the Ultimate Weapon Billet Direct Drum. This billet direct drum is made from 4140 billet steel which is to ensure the utmost safety when you consider the direct drum is traveling 2.2 times the speed of the engine. If a component fails at that speed the results are catastrophic. In competition, we've all heard about severe and potentially deadly injuries associated with transmission failures. This drum maintains conformity at higher RPMs, reducing deflection when the band is applied. This combination has proven to dramatically reduce shift times. Additional safety features included in this drum are an extended snap ring groove to allow the inclusion of more clutches. This is matched perfectly with the extended height of the SunCoast 27-spline input shaft and hub, which is also included in the Category 5 kit.

The SunCoast Category 5 48RE Rebuild Kit also includes an upgraded flexplate. The factory 48RE stamped steel flexplate is replaced with the SunCoast one-piece billet 48RE flex plate. This flexplate exceeds the competition required 29.3 SFI certification. This billet one-piece design is CNC machined from a single forging, and specific reliefs are machined out between the converter mounting area and the crank flange to enable minimal designed torsional flex.

Also included are the addition of new apply pistons for both forward and direct gearing. SunCoast Category 5 48RE master rebuild kits replace the factory cast pistons with new billet apply pistons. The direct piston is also included with new custom calibrated springs. The forward piston is replaced with a new billet piece and between these two improvements, allowance for higher clamping forces without any deflection is achieved. This leads to a greater direct shift feel and eliminates potential cross leaks within the drum.

Upgraded as well, is a full billet rear clutch retaining hub, made from 4140 heat-treated, stress-relieved billet steel in place of the OE cast piece. The factory's cast retainer is known to fail in high torsional fatigue situations such as higher line pressure, commercial use and heavy-duty towing and hauling. Replacing it with a new billet piece is the performance and reliability correction you've been looking for.

The factory intermediate shaft is substituted with a billet shaft designed for high torque & heavy towing applications. Precision machined and ground from 300 Maraging steel (VASCOMAX), it has been heat treated for superior surface toughness and durability. A billet intermediate shaft is an ideal replacement part to satisfy the demands for extreme off-road service and high-performance applications. The billet intermediate shaft is spline-machined with a large-blended radius to reduce common fractures associated with the OEM design.

Lastly, a billet output shaft. Designed for high horsepower and high torque engines, this is a performance product that has been tested well above 1,400lb-ft of torque. The shaft is machined from 300M material then Heat Treated for torsional strength and precision ground on all critical diameters.

This kit fits all 4WD 48RE transmissions.