DODGE TRUCK 1993 Service Repair Manual

21 - 240
TRANSMISSION
OVERHAUL-42RH
—
_ . *
J9121-225

Fig. 33 Installing Overrunning Clutch Rollers In Retainer—42RH
(2) Install roller and spring assembly in clutch
cam (Fig. 34).
(3) Lubricate overrunning clutch rollers, springs
cam and race with transmission fluid. Verify compo­
nent installation before proceeding. Bolt holes in
clutch cam are countersunk on one side. Be sure this side of cam will face rearward as shown (Fig. 34).
(4) Inspect bolt holes in overrunning clutch cam.
Note that one hole is not threaded. Identify location
of non threaded hole with paint mark for assembly
reference (Fig. 35).
(5) Set assembly aside for final installation after
overhaul is complete.
Fig.
32
Removing
Overrunning
Clutch
From Low-

Reverse
Drum—42RH
CLEANING
AND
INSPECTION
Clean the clutch rollers, springs and retainer,
clutch cam, low-reverse drum and overdrive piston
retainer in solvent. Dry them with light bursts of compressed air, or allow them to air dry after clean­
ing.
Inspect condition of each clutch part after cleaning.
Replace the rollers and the retainer and spring as­
sembly if the rollers, springs or spring retainer are
worn or damaged. Replace the clutch cam if worn,
cracked or damaged.
Inspect the overrunning clutch race and low-re­
verse drum. Replace the drum and race as an assem­
bly if either part is worn, scored or damaged.
Examine the overdrive piston retainer carefully for
wear, cracks, scoring or other damage. Be sure the
retainer hub is a snug fit in the case and low-reverse
drum. Replace the retainer if worn or damaged.
OVERRUNNING CLUTCH ASSEMBLY (1) Install clutch rollers in spring retainer (Fig.

33).
Be sure springs are seated squarely against roll­
ers.

Ru-Glyde, Door-Eze or similar products to prelubri-
cate seals, O-rings, and thrust washers. Petroleum
jelly can also be used to hold parts in place during reassembly.

TRANSMISSION
CASE
CLEANING
AND
INSPECTION
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent. Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear. Do not use shop towels or rags to dry the case
(or any other transmission component) unless
they are made from lint-free materials. Lint will stick to case surfaces and transmission compo­
nents and circulate throughout the transmission after assembly. A sufficient quantity of lint can
block fluid passages and interfere with valve
body operation. Inspect the case for cracks, porous spots, worn

bores,
or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear. Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way into the case. Be sure the screw turns freely.

OVERRUNNING CLUTCH-LOW-REVERSE DRUM-OVERDRIVE PISTON RETAINER
INSPECTION
AND
OVERHAUL
If the overrunning clutch and cam came out with
the low-reverse drum, remove the cam and clutch
from the drum as follows: Thread two clutch cam
bolts into the cam. Then lift the clutch and cam out of the drum with the bolts (Fig. 32). Rotate the cam
back and forth to ease removal if necessary.

•

TRANSMISSION
0VERHAUL-42RH
21 - 241

LOW-REVERSE
DRUM
OVERRUNNING
J9121-140

Fig.
34
Checking Overrunning Clutch
Installation-42RH Fig.
35
Marking Location
Of
Non-Threaded Hole
in

Clutch Cam-42RH

OIL PUMP
AND REACTION SHAFT
SUPPORT
OVERHAUL

PUMP
AND
SUPPORT DISASSEMBLY (1) Remove seal from around pump housing
(Fig.

36).

(2) Mark pump housing
and
support assembly
for

alignment reference.
(3) Loosen bolts that attach pump body
to
support
(Fig.
37).

(4) Remove pump-to-support bolts
and
separate
support from pump housing
(Fig. 38).

(5) Remove inner
and
outer gears from reaction
shaft support
(Fig. 39).
(6)
If
pump seal
was not
removed during transmis- Fig.
36
Removing Pump Housing
Seal

Fig.
37
Loosening
Pump
Support
Bolts
J9321-213

Fig.
38
Separating Pump Housing From Reaction Shaft Support-42RH

J9321-214

Fig.
39
Pump Gear Removal—42RH sion disassembly, remove seal
with punch
and
ham­

mer.

21
- 242
TRANSMISSION
OVERHAUL-42RH

•

OIL SEAL REACTION SHAFT

SUPPORT
GASKET

BOLT
(6)

O-RING
SEAL
PUMP HOUSING THRUST

WASHER

J9321-207

STRAIGHT EDGE
FEELER

GAUGE
Fig.
40 Oil
Pump
And Reaction Shaft
Support
Components—42RH

(7) Remove front clutch thrust washer from sup­
port hub (Fig. 40).

OIL PUMP
AMD
REACTION SHAFT SUPPORT

CLEANING
AND
INSPECTION
Clean pump and reaction shaft support components
with solvent and dry them with compressed air.
Inspect the pump housing and support components.
Replace the housing or support if the seal ring
grooves or machined surfaces are worn, scored, pit­
ted, or damaged.
Replace the pump gears if pitted, worn chipped, or
damaged. Inspect the thrust washer for wear or dam­
age.
Replace the washer if necessary. Note that the
inner gear used in 1993 42RH oil pumps has a new design drive lug. The new design incorpo­
rates drive flats instead of the square lug used
previously. The 1993 torque converter hub has also been redesigned to accept the new drive. If
pump gear replacement is necessary, be very sure to order and install the new style gears.
Inspect the pump and reaction shaft support bush­

ings.
Minor bushing wear is acceptable. Replace the
bushings only if scored, or severely worn. Install the gears in the pump housing and measure
end clearance with a feeler gauge and straightedge (Fig. 41). Clearance should be 0.010 - 0.06 mm
(0.0004 - 0.0025 in.).
ii!l|i"j9321-215

Fig.
41
Measuring
Pump
Gear End Clearance—42RH Measure clearance between the outer gear and the
pump body (Fig. 42). Clearance should be 0.08 - 0.19
mm (0.0035 - 0.0075 in.).
Measure gear tooth clearance with a feeler gauge.
Align one tooth of the outer gear in inner gear and
measure clearance (Fig. 43). Clearance should be 0.08 - 0.19 mm (0.0035 - 0.0075 in.).

•

TRANSMISSION
0VERHAUL-42RH
21 - 243

FEELER

GAUGE

INNER
GEAR

J9321-216
Fig. 42 Measuring Pump Housing-To-Inner Gear Clearances—42RH

INNER
GEAR

OUTER 77
GEAR
J9321-217
Fig. 43 Measuring Pump Gear Tooth Clearance—42RH

REPLACING
OIL
PUMP BUSHING
(1) Remove pump bushing with Tool Handle
C-4171 and Bushing Remover SP-3551 (Fig. 44).
(2) Install new pump bushing with Tool Handle
C-4171 and Bushing Installer SP-5117 (Fig. 44).
Bushing should be flush with pump housing bore.
SPECIAL

TOOL

C-4171

PUMP
HOUSING
BUSHING

REMOVAL

SPECIAL
TOOL

C-4171
SPECIAL
TOOL

SP-3551

BUSHING

SPECIAL
TOOL

SP-5117

BUSHING
J9221-242

Fig. 44 Removing Oil Pump Bushing—42RH (3) Stake new pump bushing in two places with
blunt punch (Fig. 45). Remove burrs from stake points with knife blade afterward.
RH282
Fig. 45 Staking Oil Pump Bushing—All

REPLACING
REACTION
SHAFT SUPPORT
BUSHING

(1) Assemble Bushing Remover Tools
SP-1191,

3633 and 5324 (Fig. 46). Do not clamp any part of
reaction shaft or support in vise. (2) Hold Cup Tool SP-3633 firmly against reaction
shaft and thread remover SP-5324 into bushing as
far as possible by hand. Then thread remover tool 3-4 additional turns into bushing with a wrench.

SPECIAL
TOOL

SP-1191
SPECIAL

TOOL

C-4171

J9221-243

Fig. 46 Replacing Reaction Shaft Support Bushing—42RH
(3) Turn remover tool hex nut down against re­
mover cup to pull bushing from shaft. Clean all chips
from shaft after bushing removal. (4) Lightly grip old bushing in vise or with pliers
and back remover tool out of bushing.
(5) Assemble Bushing Installer Tools C-4171 and
SP-5325 (Fig. 46).
(6) Slide new bushing onto Installer Tool SP-5325.
(7) Position reaction shaft support upright on a
clean smooth surface.

21
- 244
TRANSMISSION
OVERHAUL-42RH

• (8) Align bushing
in
bore. Then
tap
bushing into
place until Bushing Installer SP-5325 bottoms.
(9) Clean reaction shaft support thoroughly after
installing bushing.

ASSEMBLING
OIL
PUMP
AND
REACTION
SHAFT
SUPPORT

(1) Lubricate gear bore
in
pump housing with
transmission fluid.
(2) Lubricate pump gears with transmission fluid.
(3) Support pump housing on wood blocks (Fig. 47).
(4) Install outer gear
in
pump housing
(Fig. 47).

Gear can
be
installed either way
(it is not a
one-way

fit).
OUTER

GEAR

J9321-219

Fig.
47
Supporting
Pump
And Installing Outer
Gear-42RH
(5) Install pump inner gear (Fig. 48). Gear
can be

installed either way
(it is not a
one-way
fit).
OUTER

GEAR
INNER

GEAR

J9321-220

Fig.
48
Pump
Inner
Gear Installation—42RH
(6) Install
new
thrust washer
on hub of
reaction
shaft support. Lubricate washer with transmission
fluid or petroleum jelly.
(7)
If
reaction shaft seal rings
are
being replaced,
install
new
seal rings
on
support
hub
(Fig. 49).
Lu­
bricate seal rings with transmission fluid
or
petro­
leum jelly after installation. Squeeze each ring until
ring ends
are
securely hooked together.

CAUTION:
Th©
reaction
shaft
support
seal
rings
will
break
if
overspread,
or
twisted.
If
new rings
are
be­
ing
installed,
spread
them
only enough
for
installa­

tion.
Also
be
very sure
the
ring
ends
are
securely hooked
together
after
installation.
Otherwise,
the

rings
will
either
prevent
pump
installation,
or
break

during
installation.

SUPPORTS-
HUB Fig.
49 Hub
Seal
Ring
Position—42RH
(8) Install reaction shaft support
on
pump housing
(Fig.
50).
(9)
Align reaction support
on
pump housing.
Use

alignment marks made
at
disassembly.
Or,
rotate
support until bolt holes
in
support and pump housing are
all
aligned (holes
are
offset
for
one-way
fit).
Fig.
50
Assembling
Reaction Shaft
Support
And

Pump
Housing—42RH
(10)
Install
all
bolts that attach support
to
pump
housing. Then tighten bolts finger tight.
(11)
Tighten support-to-pump bolts
to
required
torque
as
follows:
(a) Reverse pump assembly
and
install
it in

transmission case. Position pump
so
bolts
are
fac­ ing
out
and
are
accessible.
(b) Secure pump assembly
in
case with
2 or 3

bolts,
or
with pilot studs.
(c) Tighten support-to-pump bolts
to 20 N#m (15

ft.
lbs.). (d) Remove pump assembly from transmission
case.

•

TRANSMISSION
OVERHAUL-42RH
21 - 245 (12) Install new oil seal in pump with Special Tool
C-4193 and Tool Handle C-4171 (Fig. 51). Be sure
seal lip faces inward.
(13) Install new seal ring around pump housing.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal with petroleum
jelly. Lubricate pump seal with Ru-Glyde or petro­ leum jelly.
SPECIAL

TOOL

C-4193

PUMP

BODY
FRONT

CLUTCH
SPRING
COMPRESSOR

TOOL
C-3575-A

PUMP
SEAL

J932M83
SPRING

RETAINER
\^
RETAINER

SNAP
RING
/J9121-147

Fig.
51
Pump
Oil
Seal
Installation—42RH

FRONT
CLUTCH
OVERHAUL
FRONT
CLUTCH
DISASSEMBLY

(1) Remove waved snap ring and remove pressure
plate, clutch plates and clutch discs (Fig. 52). (2) Compress clutch piston spring with Compressor
Tool C-3575-A (Fig. 53). Be sure legs of tool are seated squarely on spring retainer before compress­
ing spring.
(3) Remove retainer snap ring and remove com­
pressor tool.
Fig.
53
Compressing
Front
Clutch
Piston

Spring—42RH
(4) Remove spring retainer and clutch spring. Note
position of retainer on spring for assembly reference.
(5) Remove clutch piston from clutch retainer. Re­
move piston by rotating it up and out of retainer.
(6) Remove seals from clutch piston and clutch re­
tainer hub. Discard both seals as they are not reus­
able.
RETAINER HUB

SEAL
CLUTCH
PISTON
SNAP
RING

(WAVED)

PISTON

SPRING SPRING

RETAINER

SNAP
RING

PRESSURE
PLATE

FRONT
CLUTCH RETAINER CLUTCH PLATES
Fig.
52 Front
Clutch
Components—42RH
J9321-222

21
- 241
TRANSMISSION OWERHAUL-42RH
—

RETAINER

CHECK
BALL

J9121-368
Fig.
54 Front dutch
Piston
Retainer
Check
Ball

Location—42RH

FRONT CLUTCH ASSEMBLY (1) Soak clutch discs in transmission fluid while
assembling other clutch parts.
(2) Check piston spring fit. Trial fit each end of
spring in piston (Fig. 56). One end of spring has
slightly larger inside diameter. This end will be
slip fit over hub of piston and ensure full spring
seating. Mark spring with chalk or paint after
determining which end is best fit in spring seat. •

FRONT
CLUTCH
JC<T
7

RETAINER^
BUSHINGS
V ^====*F==^^ /

(NON-SERVICEABLE)
^Mp^^^yr^^
J9321-223

Fig.
55 Retainer
Bushing
Locations—42RH
TRIAL
FIT

SPRING
FOR

CORRECT
FIT
J9321-225
Fig.
56
Checking
Spring
Fit In
Clutch
Piston—42RH

(3) Install new seals on piston and in hub of re­
tainer. Be sure lip of each seal faces interior of clutch retainer.
(4) Lubricate lips of piston and retainer seals with
liberal quantity of Door Eze, or petroleum jelly. Then
lubricate retainer hub, bore and piston with trans­
mission fluid.
(5) Install clutch piston in retainer (Fig. 57). Use
twisting motion to seat piston in bottom of retainer. Do not attempt to push the piston straight in.
This could fold the seals over causing leakage and clutch slip.

(6)
Position spring in clutch piston.
(7) Position spring retainer on top of piston spring
(Fig. 58). Make sure retainer is properly in­
stalled. Small raised tabs should be facing up­
ward. Semicircular lugs on underside of retainer are for positioning retainer in spring.
(8) Compress piston spring and retainer with Com­
pressor Tool C-3575-A (Fig. 53). Then install new snap ring to secure spring retainer and spring.
(9) Install clutch plates and discs (Fig. 52). Install
steel plate then disc until all plates and discs are in­
stalled.
(10) Install pressure plate and waved snap ring
(Fig. 52).
FRONT CLUTCH INSPECTION
Clean the front clutch components in solvent and
dry them with compressed air only. Do not use rags
or shop towels to dry any of the clutch parts. Lint
from such materials will adhere to the component surfaces and could restrict or block fluid passages af­
ter assembly.
Replace the clutch discs if warped, worn, scored,
burned or charred, or if the facing is flaking off. Re­
place the steel plates if heavily scored, warped, or broken. Be sure the driving lugs on the plates are in
good condition. The lugs must not be bent, cracked or
damaged in any way.
Replace the clutch spring and spring retainer if ei­
ther is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.
Check action of the check ball in the retainer (Fig.

54).
The ball must move freely and not stick.
Inspect the clutch retainer bushings carefully
(Fig. 55). The retainer bushings are not service­
able. It will be necessary to replace the retainer
if either bushing is scored, or worn.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.

TRANSMISSION
OVERHAUL-42RH
21 - 247

FRONT

CLUTCH

RETAINER FEELER GAUGE

J9121-146
Fig.
57 Front
Clutch
Piston
Installation—42RH

SMALL TABS
ON RETAINER
-
FACE UPWARD
J9321-224
Fig.
58 Correct
Spring
Retainer Installed
Position—42RH
(11) Check clutch plate clearance (Fig. 59). Clear­
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.).
If clearance is incorrect, clutch discs, plates pressure
plates and snap ring may have to be changed.

REAR
CLUTCH OVERHAUL

REAR CLUTCH DISASSEMBLY (1) Remove fiber thrust washer from forward side
of clutch retainer.
(2) Remove selective clutch pack snap ring (Fig.

60).

(3) Remove top pressure plate, clutch discs, steel

plates,
bottom pressure plate and wave spring (Fig.
60).

(4) Remove clutch piston. Grasp piston and rotate
piston up and out of retainer. (5) Remove and discard piston seals.
(6) Remove input shaft snap ring (Fig. 61).
(7) Press input shaft out of retainer with shop
press and suitable size press tool (Fig. 62).
(8) Remove input shaft front/rear seal rings.
REAR CLUTCH INSPECTION Clean the clutch components with solvent and dry
them with compressed air. Do not use rags or shop
towels to dry any of the clutch parts. Lint from such
FEELER GAUGE

RH288

Fig.
59
Measuring
Front
Clutch
Pack
Clearance materials will adhere to component surfaces and
could restrict or block fluid passages after assembly.
Replace the clutch discs if warped, worn, scored,
burned/charred, the lugs are damaged, or if the fac­ ing is flaking off. Replace the top and bottom pres­
sure plates if scored, warped, or cracked. Be sure the
driving lugs on the pressure and clutch plates are also in good condition. The lugs must not be bent,
cracked or damaged in any way.
Replace the piston spring and wave spring if either
part is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The
clutch and pressure plates should slide freely in the

slots.
Replace the retainer if the grooves are worn or
damaged. Also check action of the check ball in the
piston. The check ball must move freely and not stick. Replace the retainer bushing if worn, scored, or
doubt exists about bushing condition. Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored. Check condition of the fiber thrust washer and
metal output shaft thrust washer. Replace either
washer if worn or damaged. Check condition of the seal rings on the input shaft
and clutch retainer hub. Replace the seal rings only
if obviously damaged. The input shaft front seal ring
is teflon with chamfered ends. The rear ring is metal
with interlocking ends.

21
- 248
TRANSMISSION
0VERHAUL-42RH

REAR

CLUTCH
PISTON CLUTCH
PISTON
SEALS
OUTPUT

SHAFT
THRUST
WASHER
(METAL)
INPUT

SHAFT SNAP RING REAR

CLUTCH

RETAINER
INPUT

SHAFT
-REAR

CLUTCH

.
THRUST

^
/ SHAFT
WA|HER
/
FRONT
(FIBER)

SHAFT
SEAL
REAR RING
-M„u
SEAL (TEFLON)
C^H

RING
PACK

(METAL) SNAP
RING

(SELECTIVE)
PISTON
SPRING
BOTTOM

PRESSURE PLATE
CLUTCH
DISCS
(4)
TOP
PRESSURE PLATE

J9121-539

Fig.
60
Rear
Clutch
Components—42RH

Fig.
61
Removing/Installing Input Shaft
Snap
Ring-42RH
Check
the
input shaft
for
wear,
or
damage. Replace
the shaft
if
worn, scored
or
damaged
in any way.

REAR
CLUTCH ASSEMBLY
(1) Soak clutch discs
in
transmission fluid.
(2) Install
new
seal rings
on
clutch retainer
hub

and input shaft (Figs.
63 and 64).
J912M50

Fig.
62
Removing
Input Shaft From Rear
Clutch
Retainer—42RH (a)
Be
sure clutch
hub
retainer seal ring
is
fully
seated
in
groove
(Fig. 63).
Ring must
not be

twisted,
or
distorted. (b) Note that input shaft front seal ring
is
teflon
and rear seal ring
is
metal (Fig. 64).
Be
sure cham­
fered ends
of
teflon ring
are
properly joined
and

that ends
of
rear ring
are
securely hooked together.
(c) Lubricate retainer
and
shaft seal rings with
light coat
of
petroleum jelly after installation.

•

TRANSMISSION
OVERHAUL-42RH
21 - 24S
J9121-538

Fig.
63 Installing Rear
Clutch
Retainer And Input

Shaft
Seal
Rings—42RH

J912M51
Fig.
64 input Shaft
Seal
Ring
Identification—42RH
(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then press input shaft into retainer (Fig. 65).
(4) Install input shaft retaining ring (Fig. 61).
(5) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
(6) Lubricate lip of piston seals with liberal quan­
tity of Door Eze, or petroleum jelly. Then lubricate
retainer hub and bore with transmission fluid.
Fig.
65
Pressing
Input Shaft Into Rear
Clutch

Retainer—42RH (7) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. Do not attempt to push the piston straight in. This
could fold the seals over causing leakage and
clutch slip.
(8) Install piston spring in retainer and on top of
piston (Fig. 56). Concave side of spring faces up as shown.
(9) Install wave spring in retainer (Fig. 66). Be
sure spring is completely seated in retainer groove.

Fig.
66
Piston
And Wave
Spring
Position—42RH
(10) Install bottom pressure plate (Fig. 60). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.