DODGE TRUCK 1993 Service Repair Manual

21
- 220
TRANSMISSION OVERHAUL—36RH/37RH

•
VALVE
BODY CLEANING AND INSPECTION
The only serviceable valve body components are

the:

• park lock rod and E-clip
• switch valve and spring
• pressure adjusting screw bracket
• throttle valve lever
• manual shaft
• manual shaft seal/washer/E-clip/detent ball
• fluid filter.
The remaining valve body components are serviced
only as part of a complete valve body assembly (Fig.

92).
Clean the valve body components in a parts clean­
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution.
Dry the parts with compressed air. Make sure all
passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe
off valve body components unless they are made
from lint free material. Lint will adhere to the
valve body components causing valve bind. Lint
can also clog filters and small fluid passages.
Inspect the throttle and manual valve levers and

shafts.
Do not attempt to straighten a bent shaft
or correct a loose lever. Replace these compo­
nents if worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight­
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with cro­
cus cloth. Position the crocus cloth sheet on a surface
plate, sheet of plate glass, or equally flat surface. If distortion is severe or any surfaces are heavily
scored, the valve body will have to be replaced.

CAUTION:
The
throttle
valve, shuttle valve plug,
1-2

shift valve
and 1-2
governor plug
are
made
of

coated aluminum. Aluminum components
can be
identified
by the
dark color
of the
special coating
applied
to the
surface
(or by
testing
with
a
magnet).
DO
NOT
polish
or
sand
aluminum valves
or
plugs

with
any
type
of
material,
or
under
any
circum­
stances.
This practice
will
remove
the
special coat­
ing
and
cause
the
valves
and
plugs
to
stick
and
bind.

Inspect the valves and plugs for scratches, burrs,

nicks,
or scores. Also inspect the coating on the alu­
minum valves and plugs. If the coating is damaged
or worn through, the valve (or valve body) should be
replaced.
Aluminum valves and plugs must not be sanded or
polished under any circumstances. However, minor burrs or scratches on steel valves and plugs can be
removed with crocus cloth but do not round off the
valve or plug edges. Squareness of these edges is vi­
tally important; they prevent foreign matter from lodging between the valves and plugs and the bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors. Re­
place the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken

coils.

Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with

use.
If the valve body functioned correctly when new,
it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in han­
dling.
VALVE BODY ASSEMBLY

CAUTION:
Do not
force
the
valves
or
plugs
into place during reassembly.
If the
valve body bores

and
the
valves
and
plugs
are
free
of
distortion
or
burrs,
the
valves
and
plugs
should slide into place

easily.
In
addition,
do not
overtighten
the
transfer plate
and
valve body screws during reassembly.
Overtightening
can
distort
the
valve body resulting
in valve sticking,
cross
leakage
and
unsatisfactory
operation. Tighten
the
screws
alternately
and

evenly
to 4 Nnn (35 in.
lbs.) torque only.

(1) Lubricate valve body bores, valves and plugs
with ATF Plus, or Dexron II™ transmission fluid.
(2) Insert rear clutch check ball in transfer plate
and install filter in separator plate (Fig. 93).
SEPARATOR
TRANSFER

PLATE PLATE

FILTER
BALL
J9121-82

Fig.
93 Installing
Filter
and Rear
Clutch
Check
Bali—36RH/37RH

•

TRANSMISSION
OVERHAUL—36RH/37RH
21 - 221 (3) Align and install separator plate on transfer
plate (Fig. 94). (4) Verify rear clutch check ball position before se­
curing separator plate (Fig. 95). Ball should be visi­
ble in fifth orifice at lower right side of separator plate as shown.
(5) Install stiffener plate on separator plate. Then
secure separator and stiffener plates to transfer plate
with short attaching screws. Tighten screws to 4 Nnn (35 in. lbs.) torque. 1/4"
DIAMETER

CHECK
BALLS
TRANSFER

PLATE
SEPARATOR

PLATE
J9121-83

Fig.
94 Installing Separator Plate—36RH/37RH f^-^. )
REAR CLUTCH-

J9121-53-

Fig.
95
Verifying
Rear
Clutch
Check
Ball
Position-36RH/37RH (6) Position valve body so internal passages and
check ball seats are facing upward. Then install
check balls in valve body (Fig. 96). There are a total
of 7 check balls. Single large check ball has a diam­ eter of approximately 11/32 inch. Remaining 6 check
balls have a diameter of approximately 1/4 inch.
(7) Align and install transfer/separator plate as­
sembly on valve body (Fig. 97). Install screws attach­
ing transfer plate to valve body. Tighten screws alternately and in a diagonal pattern to 4 Nnn (35
in. lbs.) torque.
(8) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring (Fig. 98). Insert as­
sembly in valve body and install end plate. Tighten
end plate screws to 4 Nnn (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 shift valves and springs
(Fig. 98).
11/32"
DIAMETER

CHECK
BALL
J9121-84

Fig.
96 Correct Position Of
Valve
Body Check

Balis-36RH/37RH
TRANSFER
PLATE/

SEPARATOR
PLATE ASSEMBLY
VALVE
BODY
J9121-85

Fig.
97 Installing Transfer
Plate
On
Valve
Body-36RH/37RH
(10) Install 1-2 shift control valve and spring (Fig.
98) (11) Assemble 3-2 downshift housing (Fig. 92). In­
stall throttle plug, limit valve and spring and secure
in housing with retainer.
(12) Position shift valve end plate on 3-2 downshift
housing. Then align housing and end plate on valve
body. Carefully compress shift valve springs and in­ stall screws that secure housing and end plate to
valve body (Fig. 91). Tighten screws to 4 Nnn (35 in.
lbs.) torque.
(13) Install shuttle valve as follows. (a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second­
ary spring. (c) Install secondary spring on end of valve.
(d) Hold shuttle valve in place.
(e) Compress secondary spring and install E-clip
in groove at end of shuttle valve. Verify that
spring and E-clip are properly seated before pro­
ceeding. (14) Install shuttle valve cover (Fig. 99) and cover
screws to 4 Nnn (35 in. lbs.) torque. (15) Install 1-2 and 2-3 valve governor plugs. Then
install shuttle valve primary spring and throttle plug (Fig. 99).

21 - 222 TRANSMISSION
OVERHAUL-86RH/37RH

REGULATOR VALVE

SPRING

THROTTLE

PRESSURE
PLUG

2-3

SHIFT

VALVE AND

SPRING
SLEEVE

SWITCH VALVE
LINE

PRESSURE

REGULATOR VALVE
1-2

SHIFT

VALVE AND

SPRING
1-2

SHIFT

CONTROL VALVE AND

SPRING
Fig. 98 Shift
Valve
And Spring installation-36RH/37RH

LINE

PRESSURE
PLUG
J9121-86

SHUTTLE
VALVE
END PLATE

SECONDARY

SPRING
&
GUIDES
SHUTTLE VALVE

PRIMARY
SPRING

SHUTTLE VALVE

THROTTLE
PLUG
GOVERNOR
PLUG-

END PLATE
J9121-50

Fig.
99
Control
Valve
Locations—36RH/37RH

•

TRANSMISSION
OVERHAUL—36RH/37RH
21 - 223 (16) Align and install governor plug end plate
(Fig. 99) on valve body and install end plate screws.
Tighten screws to 4 N»m (35 in. lbs.) torque.
(17) Install manual valve (Fig. 99). (18) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 99). (19) Install pressure regulator valve and switch
valve (Fig. 99).
(20) Install manual lever detent spring in housing.
Place detent ball on end of spring and push ball and spring into housing. Secure ball and spring with Re­
tainer Tool 6583 (Fig. 88).
(21) Insert line pressure adjusting screw in adjust­
ing screw bracket (Fig. 92).
(22) Place valve spring on end of line pressure reg­
ulator valve.
(23) Install switch valve spring on tang at end of
adjusting screw bracket (Fig. 87). (24) Install adjusting screw bracket on valve body.
Align springs, press bracket toward valve body and install long bottom bracket attaching screw first. Do
not tighten screw fully at this time.
(25) Carefully align bracket on valve body and
transfer plate and install remaining (two) bracket screws. Verify that valve springs and bracket are
properly aligned. Then tighten all three bracket screws to 4 N*m (35 in. lbs.) torque.
(26) Install throttle lever in valve body. Then in­
stall manual lever over throttle lever and start man­
ual lever into valve body.
(27) Align manual lever detent with detent ball
and align lever arm with manual valve. Hold throt­
tle lever upward. Then press down on manual lever until lever is fully seated.
(28) Install manual lever seal, washer and retain­
ing E-clip.
(29) Lubricate shaft of manual lever with light
coat of petroleum jelly. This will help protect seal lip
when manual shaft seal is installed.
(30) Verify that throttle lever is aligned with end
of kickdown valve stem and that manual lever arm
is engaged in manual valve (Fig. 100).
(31) If line pressure and/or throttle pressure ad­
justment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as
described in Valve Body Control Pressure Adjust­
ment procedure.

VALVE BODY CONTROL
PRESSURE

ADJUSTMENTS

There are two control pressure adjustments on the
valve body which are, line pressure and throttle pres­
sure.
Line and throttle pressures are interdependent be­
cause each affects shift quality and timing. As a re-
Fig.
100 Manual And
Throttle
Lever

Alignment-36RH/37RH
suit, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.

Line
Pressure
Adjustment Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel scale (Fig. 101).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting. The 33.4 mm (1-5/16 in.) setting is an approxi­
mate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa). Turn­
ing the adjusting screw counterclockwise increases
pressure while turning the screw clockwise decreases
pressure.
Fig.
101
Line
Pressure
Adjustment—36RH/37RH

21
- 224
TRANSMISSION
OVERHAUL—36RH/37RH

• Throttle
Pressure
Adjustment
Insert Gauge Tool
C-3763
between the throttle le­
ver cam and the kickdown valve stem (Fig. 102).
Push the gauge tool inward to compress the kick-
down valve against the spring and bottom the throt­
tle valve. Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until the screw head
touches throttle lever tang and the throttle lever cam
touches gauge tool. The kickdown valve spring must be fully com­
pressed and the kickdown valve completely bot­
tomed to obtain correct adjustment.

HEX

WRENCH
THROTTLE

LEVER
SPECIAL

TOOL
C-3763
J9121-542

Fig.
102
Throttle
Pressure
Adjustment—36RH/37RH

TRANSMISSION
ASSEMBLY
AND
ADJUSTMENT

ASSEMBLY
TIPS
Do not allow dirt, grease, or foreign material to en­
ter the case or transmission components during as­ sembly.
Keep the transmission case and components clean.
Also make sure the tools and workbench area used
for reassembly operations are equally clean.
Shop towels used for wiping off tools and your
hands must be made from lint free materials. Lint
will adhere to transmission parts and could interfere
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components
with Mopar ATF Plus, type 7176 transmission fluid
during reassembly. This is the preferred fluid for use in 36RH/37RH transmissions. Use Mopar Dexron II
only when ATF Plus is not readily available.
Use Ru-Glyde, or Door-Eze, or petroleum jelly on
seals and O-rings to ease installation. Petroleum
jelly can also be used to hold thrust washers and plates in position during assembly operations. How­ever, do not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of lubricants can eventually block or re­ strict fluid passages and valve operation.
Do not force parts into place. Most of the transmis­
sion components/sub-assemblies are easily installed
by hand. If a part seems difficult to install, it is ei­ ther misaligned or incorrectly assembled. Verify that thrust washers, thrust plates and seal rings are cor­
rectly positioned. These parts will prevent proper as­
sembly is mispositioned (or "left out" by accident. The planetary geartrain, front/rear clutch assem­
blies and oil pump are all much easier to install
when the transmission case is upright or as close to
this position as possible. Either tilt the case upward
with wood blocks, or cut a hole in the bench large enough for the output shaft and rear support. Then lower the shaft and support into the hole and support
the rear of the case directly on the bench.

Assembly
Procedure
(1) Lubricate rear servo piston seal with petroleum
jelly, Ru-Glyde, or Door Eze. Lubricate servo bore in case with transmission fluid. (2) Install rear servo piston in case. Position piston
at slight angle to bore and insert piston with twist­
ing motion (Fig. 103).
REAR

SERVO

PISTON

J9121-87>

Fig.
103 Installing Rear
Servo
Piston—36RH/37RH
(3) Install rear servo spring and retainer in case
bore (Fig. 104). Be sure spring is seated on piston.

SPRING

RETAINER

v-'
J9121-88

Fig.
104 Installing Rear
Servo
Piston
Spring
And Retainer-36RH/37RH

•

TRANSMISSION
OVERHAUL—36RH/37RH
21 - 225 (4) Compress rear servo piston with C-clamp or
Valve Spring Compressor C-3422-B and install servo
piston snap ring (Fig. 105).
Fig.
105 Installing Rear
Servo
Snap
Ring—36RH/

37RH (5) Install overrunning clutch cam, springs, rollers,
race and rear support if not yet installed. Refer to in­ stallation procedure in Subassembly Overhaul sec­
tion.
(6) Position rear band and link in case (Fig. 106).
Be sure notched side of link faces away from
band.

Fig.
106 Installing Rear
Band
And
Link—36RH/37RH
(7) Install low-reverse drum (Fig. 107). Slide drum
through rear band, onto rear support hub and into engagement with overrunning clutch race.
Fig.
107 Installing
Low-Reverse
Drum—36RH/37RH

(8) Install snap ring that secures low-reverse drum
to rear support hub (Fig. 108).

Fig.
108 Installing
Low-Reverse
Drum
Snap
Ring—36RH/37RH

(9) Install new O-rings on band reaction pin. Lu­
bricate pin and O-rings. Then insert pin into case and part way into band link (Fig. 109).
(10) Install rear band adjusting lever, strut and re­
action lever (Fig. 110). Be sure levers and strut are
aligned and engaged before seating band reaction pin
in case.

21
- 226
TRANSMISSION
OVERHAUL—36RH/37RH

•

REACTION PIN
O-RINGS
J9121-91

Fig.
109 Installing Rear
Band
Reaction
Pin—36RH/
37RH

ADJUSTING
SCREW
ADJUSTING

LEVER

REACTION LEVER
•STRUT

J9121-92

Fig.
110 Rear
Band
Levers
And Strut—36RH/37RH (11) Lubricate front servo piston components and
servo bore in case with transmission fluid.
(12) Install front servo piston in bore. Carefully
"run" small, suitable tool around piston ring to press
it back into groove and ease installation (Fig. 111).
Rotate piston into bore at same time. Rock piston
slightly to ease piston ring past snap ring groove and
into bore.
(13) Bottom front servo piston in bore and install
servo spring.
(14) Install front servo piston rod guide as follows: (a) Place Tool SP-5560 (or similar size tool) on
guide to serve as press tool for C-clamp. (b) Position C-clamp on press tool and case (Fig.

112).
USE
SUITABLE
TOOL

TO HELP SEAT PISTON RING

FRONT

SERVO

PISTON
-J9121-98

Fig.
111 Installing Front
Servo
Piston—36RH/37RH
(c) Slowly compress rod guide while simulta­
neously easing seal ring into bore with suitable
tool (tighten clamp screw with one hand and "run"
tool around guide ring with other hand). (15) Install rod guide snap ring (Fig. 112).

C-CLAMP
ROD
SMALL
GUIDE SCREWDRIVER
ROD

GUIDE
SNAP
RING

J9121-99"
Fig.
112 Installing Front
Servo
Rod
Guide
And
Snap

Ring—36RH/37RH

(16) Position front band lever in case and over
servo rod guide. Then install front band reaction pin
in case and slide it through lever.
(17) Coat threads of front band reaction pin access
plug with sealer and install it in case. Tighten plug to 17 Nnn (13 ft. lbs.) torque.
(18) Install assembled output shaft and planetary
gear components (Fig. 113). Support shaft care-

•
fully during Installation. Do not allow shaft
bearing/bushing surfaces to become nicked or
scratched. ASSEMBLY JY,iM^

Fig.
113 installing Output Shaft And Planetary Geartrain-36RH/37RH (19) Align and install governor/park gear assembly
on output shaft. Note that output shaft In current
transmission is spotfaced for governor valve end clearance (Fig. 114). Shaft must be indexed so
that small end of governor valve will seat in this spotface. Install governor body and park as fol­
lows to ensure proper alignment and operation.
(a) Rotate output shaft until spotface (at gover­
nor valve shaft hole) is facing upward (Fig. 114). (b) Position valve bore in governor body over
spotface on output shaft. Then align valve shaft
holes in governor body and output shaft.
(c) Align splines in output shaft and park gear

hub.
J9221-52
TRANSMISSION
OVERHAUL—36RH/37RH
21 - 227

Fig.
115 Installing
Governor
And
Park
Gear
Assembly-36RH/37RH
(d) Carefully push assembly into place in rear
support (Fig. 115).
(e) Verify that governor valve shaft holes in out­
put shaft and governor body are still in alignment. Reposition governor body and park gear if align­
ment is not correct.
(f) Tighten bolts attaching governor body to park
gear to 11 N-m (95 in. lbs.) torque. (20) Assemble and install governor valve and shaft
(Fig. 116). Be sure valve shaft operates freely be­
fore proceeding.
Fig.
114
Governor
Valve
And Output Shaft Spotface
Alignment-36RH/37RH
Fig.
116 Installing
Governor
Valve
And
Shaft-36RH/37RH

21 - 228
TRANSMISSION
OVERHAUL—36RH/37RH

• (21) Install E-clips that retain governor valve shaft
(Fig. 117). One clip is required at each end of shaft.
Fig.
117 Installing
Governor
Valve
Shaft

E-CIips-36RH/37RH
(22) Lubricate output shaft thrust plate with petro­
leum jelly and install plate on output shaft hub (Fig.
118).
Fig.
118 Installing Output Shaft Thrust Plate-36RH/ 37RH
(23) Check input shaft front seal rings, fiber thrust
washer and rear seal ring (Fig. 119). Be ends of rear seal ring are hooked together and diagonal cut ends
of front seal rings are firmly seated against each
other as shown. Lubricate seal rings with petroleum
jelly after checking them.
(24) Assemble front and rear clutches (Fig. 120).
Align lugs on front clutch discs. Mount front clutch
Fig.
119 Input Shaft
Seal
Ring
And Thrust
Washer

instaliation-36RH/37RH on rear clutch. Turn front clutch retainer back and
forth until front clutch discs are fully seated on rear clutch splined hub.

Fig.
120
Assembling
Front And Rear
Clutches~36RH/37RH

(25) Measure thickness of output shaft thrust
washer with micrometer. Record thickness for refer­ ence when checking input shaft end play.
(26) Install output shaft thrust washer in hub rear
clutch retainer (Fig. 121). Use petroleum jelly to hold

•
TRANSMISSION
OVERHAUL—36RH/37RH
21 - 229
washer in place. Position washer so grooves are
facing outward. Also note that washer only fits
one way in clutch retainer hub.

Fig.
121 Installing Output Shaft Thrust
Washer-36RH/37RH

(27) Slide front band onto driving shell but do not
install band strut or anchor at this time. (28) Place transmission case in upright position, or
place blocks under front end of transmission repair stand to tilt case rearward. This makes it easier to
install front/rear clutch assembly.
(29) Align discs in rear clutch. Then install and
engage assembly in front planetary and driving shell (Fig. 122). Turn clutch retainers back and forth until
both clutches are seated.
(30) Slide front band over front clutch retainer and
install front band strut and anchor (Fig. 123).
(31) Tighten front band adjusting screw until band
is tight on clutch retainer. Verify that front/rear
clutch assembly is still properly seated before tight­
ening band.
(32) Install oil pump Pilot Studs C-3288-B in case
(Fig. 124). (33) Install new oil pump gasket on pilot studs and
seat it in case. Be sure gasket is properly aligned
with fluid passages in case (Fig. 124). J9121-18
Fig.
123 Front
Band
Linkage
Installation—36RH/

37RH