DODGE TRUCK 1993 Service Repair Manual

21
- 271
TRANSMISSION
OWERHAUL-42RH

•

SERVO

PISTON PISTON

SPR
NG
SNAP

RING

PISTON
SEAL
RETAINER
J9121-343

Fig.
130 Rear
Servo
Components—42RH

PISTON
SEAL

RINGS
SERVO
PISTON

SNAP
RING
(4) Examine bolt holes in overrunning clutch cam.
Note that one hole is not threaded (Fig. 133). This
hole must align with blank area in clutch cam bolt
circle (Fig. 134). Mark hole location on clutch cam and blank area in case with grease pencil, paint
stripe, or scribe mark for assembly reference.
NON-THREADED
HOLE
OVERRUNNING CLUTCH
CAM
J9121-226

ROD

ROD
SPRING GUIDE
J9121-344

Fig.
131 Front
Servo
Components—42RH

(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap ring (Fig. 132).
SPRING

COMPRESSOR
TOOL

C-3422-B

ROD

QUIDE
SNAP
RING
J9121-136

Fig.
132
Compressing
Front/Rear
Servo
Springs
Fig.
133 Location Of Non-Threaded Hole In
Clutch

Cam-42RH

S>
OVERRUNNING CLUTCH
CAM

SEAT
IN
CASE 40N-THREADED
HOLE
IN
CLUTCH CAM ALIGNS

HERE
(BLANK AREA) OF SEAT
i
J9121-541

Fig.
134 Location Of
Blank
Area In
Clutch
Cam
Bolt
Circle-42RH
(5) Mark location of non-threaded hole in clutch
cam and blank area in bolt circle with grease pencil.
(6) Align and install overrunning clutch and cam
in case (Fig. 135). Be sure cam is correctly in­ stalled. Bolt holes in cam are slightly counter­sunk on one side. Be sure this side of cam faces
rearward (toward piston retainer).
(7) Verify that non-threaded hole in clutch cam is
properly aligned. Check alignment by threading a
bolt into each bolt hole. Adjust clutch cam position if necessary.
(8) Install and tighten overrunning clutch cam
bolts to 17 N«m (13 ft. lbs.) torque. Note that clutch cam bolts are shorter than piston retainer bolts.

•

Fig.
135 Overrunning
Clutch
Installation—42RH (9) Lubricate clutch cam rollers with transmission
fluid.
(10) Install rear band reaction pin (Fig. 136). Be
sure pin is fully seated in case.
Fig.
136 Installing Rear
Band
Reaction
Pin—42RH

(11) Install rear band in case (Fig. 137). Be sure
twin lugs on band are seated against reaction pin.
(12) Install low-reverse drum and check overrun­
ning clutch operation as follows:
(a) Lubricate overrunning clutch race (on drum
hub) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start race (on drum
hub) into overrunning clutch rollers. (d) Press drum rearward and turn it in clockwise
direction until drum seats in overrunning clutch (Fig. 138). (e) Turn drum back and forth. Drum should ro­
tate freely in clockwise direction and lock in
counterclockwise direction (as viewed from
front of case). (13) Install new gasket at rear of transmission

case.
Use petroleum jelly to hold gasket in place. Be
TRANSMISSION
0VERHAUL-42RH
21 - 271

Fig.
137 Rear
Band
Installation—42RH

Fig.
138 Installing
Low-Reverse
Drum—42RH
sure to align governor feed holes in gasket with feed
passages in case (Fig. 139). Also install gasket before overdrive piston retainer. Center hole in gasket is
smaller than retainer and cannot be installed over
retainer.
(14) Install overdrive piston retainer. Be sure gov­
ernor tube bores in retainer are aligned with gover­
nor feed passages in gasket and case (Fig. 140).
Install and tighten retainer bolts to 17 N#m (13 ft. lbs.) torque.
(15) Install snap ring that secures low-reverse
drum to hub of piston retainer (Fig. 141). (16) Install rear band lever and pivot pin (Fig.

142).
Align lever with pin bores in case and push
pivot pin into place.

21
- 272
TRANSMISSION
OVERHAUL-42RH

Fig. 139 Installing/Aligning
Case
Gasket—42RH

Fig.
140 installing Overdrive
Piston
Retainer—42RH (17) Install planetary geartrain assembly (Fig.
143)
(18) Install thrust plate on intermediate shaft hub
(Fig. 144). Use petroleum jelly to hold thrust plate in
place.
(19) Check seal ring on rear clutch retainer hub
(Fig. 49) and seal rings on input shaft (Fig. 145).
Verify that diagonal-cut ends of teflon seal rings are
properly joined and ends of metal ring are correctly
Fig.
141 Installing
Low-Reverse
Drum
Retaining

Snap
Ring

Fig.
142 Rear
Band
Lever
And Pivot Pin
Installation
hooked together. Also verify that shaft seal rings are
installed in sequence shown.

(20)
Check rear clutch fiber thrust washer (Fig.

146).
Use additional petroleum jelly to hold washer
in place if necessary.
(21) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 147). Rotate front
clutch retainer back and forth until completely seated on rear clutch.
(22) Coat intermediate shaft thrust washer with
petroleum jelly. Then install washer in rear clutch
hub (Fig. 148). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer faces rearward (toward output shaft) as shown.
Also note that washer only fits one way in clutch hub.

•

TRANSMISSION
OVERHAUL-42RH
2"! - 273

J9121-217

Fig.
143 installing Planetary Geartrain—42RH
INTERMEDIATE

SHAFT
HUB
INTERMEDIATE

SHAFT

THRUST
PLATE

J9121-215

Fig.
144 installing
intermediate
Shaft Thrust
Plate
(23) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 149). This makes installation
on front planetary easier.
(24) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to in­
stall if transmission is as close to upright position as
possible.
(25) Install front and rear clutch units as assembly
(Fig. 150). Align rear clutch with front annulus gear
and install assembly in driving shell. Re sure out­
put shaft thrust washer and thrust plate are not displaced during installation.
INPUT

SHAFT
TEFLON

SEAL

/
RING

METAL
SEAL

RING

Fig.
145 Input Shaft
Seal
Ring
Location-42RH REAR

CLU1CH

^ETA'Mnk
Fig,
146 Installing Rear
Clutch
Thrust

Washer-42RH
REAR

CLUTCH

ASSEMBLY
i
i
JfiN
"
FRONT
CLIPCr

BACK & FO-TH { UNTIL i
SEATED

J9121-190

Fig.
147
Assembling
Front And Rear
Clutch
Units-42RH
(26) Carefully work assembled clutches back and
forth to engage and seat rear clutch discs on
front

21
- 274
TRANSMISSION
0WERHAUL-42RH
INTERMEDIATE
SHAFT THRUST
WASHER
INPUT
SHAFT FRONT
CLUTCH
REAR

'CLUTCH

REAR

CLUTCH

RETAINER

HUB
INPUT
SHAFT
J9121-214
J9121-124

Fig.
148 Installing
Intermediate
Shaft Thrust
Washer-42RH
Fig.
150 Installing Front/Rear
Clutch

Assemblies—42RH

REAR

CLUTCH
DISCS

USE

SMALL

SCREWDRIVER
TO
ALIGN
CLUTCH DISC TEETH
^J9121-192
:FRONT

BAND

FRONT
BAND

REACTION PIN
FRONT
CLUTCH

RETAINER

J912M93
Fig.
149
Aligning
Rear
Clutch
Disc Lugs—42RH

annulus gear. Also be sure front clutch drive lugs are
fully engaged in slots of driving shell after installa­
tion.
(27) Slide front band over front clutch retainer
(Fig. 151).
(28) Insert front band reaction pin part way into
case (Fig. 151).
(29) Install front band lever, strut and adjusting
screw (Fig. 152).
(30) Push front band reaction pin completely into
place. Then tighten band adjusting screw until band
just grips clutch retainer. Verify that front/rear clutches are still seated before continuing. (31) Coat band reaction pin access plug with sealer
and install plug in converter housing.
Fig.
151 Installing Front
Band
And Reaction
Pin-42RH (32) Check seal rings on reaction shaft support

hub.
Verify that seal rings are hooked together and that front clutch thrust washer is properly positioned (Fig. 153). Use extra petroleum jelly to hold thrust
washer in place if necessary.
(33) Thread two Pilot Stud Tools C-3288-B into
bolt holes in oil pump flange (Fig. 154). (34) Align and install oil pump gasket (Fig. 154).
(35) Lubricate oil pump body seal with Ru-Glyde,
or petroleum jelly. Lubricate pump shaft seal lip
with petroleum jelly.
(36) Install oil pump (Fig. 155). Align and position
pump on pilot studs. Slide pump down studs and

•

BAND BAND

Fig.
152 Front
Band
Linkage
Installation—42RH
SEAL

RINGS
J9121-194

Fig.
153 Reaction Shaft
Support
Seal
Rings
And Front
Clutch
Thrust
Washer
Position—42RH
work it into front clutch hub and case by hand. Then
install 2 or 3 pump bolts to hold pump in place. (37) Remove pilot stud tools arid install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 N*m (15 ft. lbs.).
(38) Measure input shaft end play (Fig. 156). At­
tach dial indicator to converter housing. Position in­ dicator plunger against input shaft and zero indicator. Move input shaft in and out and record
reading. End play should be 0.56 - 2.31 mm (0.022 - 0.091 in.).
(39) Install new seals on overdrive piston. Then lu­
bricate seals with Ru-Glyde, Door-Eze or petroleum
jelly. (40) Install overdrive piston in retainer. Align lo­
cating lugs on piston in locating bores in re­
tainer (Fig. 157). Use thin plastic strip or feeler gauge to help guide piston outer seal into retainer. (41) Install spacer on intermediate shaft, if not
previously installed.
TRANSMISSION
0VERHAUL-42RH
21 - 275

Fig.
154 Installing Pilot
Studs
And Oil
Pump
Gasket-42RH
Fig.
155 Installing Oil
Pump
Assembly
In

Case—42RH

(42) Install overdrive piston thrust plate (Fig. 158).
Use liberal quantity of petroleum jelly to hold thrust
plate in position on piston. (43) Install overdrive piston thrust bearing in di­
rect clutch hub (Fig. 159). Use liberal quantity of pe­
troleum jelly to hold thrust bearing in place. Note
that one side of bearing has dark coated sur­
face. This surface faces overdrive piston. Also
be sure raised shoulder on inside diameter of
bearing faces forward as well.
(44) Apply small amount of petroleum jelly to pilot
hub of intermediate shaft.
(45) Verify alignment of splines in overdrive unit
planetary gear and overrunning clutch. Be sure

21
- 276
TRANSMISSION
OVERHAUL-42RH

OVERDRIVE
RETAINER LUG

BORES
Fig.
156 Measuring input Shaft End Play

PISTON
LOCATING
LUGS

J9121-353

Fig.
157 Overdrive Piston Alignment—42RH Alignment Tool 6227-2 is still fully seated (Fig. 160).
If planetary gear and overrunning clutch splines
become misaligned, overdrive unit cannot be
fully installed on intermediate shaft. Overdrive unit will have to be disassembled in order to re­align splines.
(46) Carefully withdraw alignment tool from over­
drive unit.
OVERDRIVE
PISTON

THRUST
PLATE

J9121-354

Fig.
158 Installing Overdrive Piston Thrust Plate-42RH

BE
SURE

THIS
SHOULDER
OVERDRIVE PISTON

THRUST
IARINC
Fig.
159 Installing Overdrive Piston Thrust
Bearing—42RH

SPECIAL

TOOL
6227-2

J9221-36

Fig.
160
Checking
Alignment Of Overdrive Planetary
Gear
And Overrunning
Clutch
Splines—42RH

•

TRANSMISSION
OVERHAUL-42RH
21 - 277 (47) Lubricate intermediate shaft splines and bushing
surfaces with transmission fluid or petroleum jelly.
(48) Install overdrive unit. Be sure governor tubes
are aligned with feed holes in piston retainer boss. Note that intermediate shaft is snug fit in overdrive
planetary gear and overrunning clutch. If overdrive unit will not seat fully, rotate overdrive output shaft slightly to align splines and try again.
(49) Apply 1-2 drops of Mopar thread adhesive (or
Loctite 242) to overdrive unit attaching bolts. Then install and tighten bolts to 34 N« (25 ft. lbs.) torque.
(50) Install accumulator inner spring, piston and
outer spring (Fig. 161).
ACCUMULATOR
OUTER

Fig.
161 Installing
Accumulator
Piston
And
Springs—42RH
(51) Verify that park/neutral position switch has
not been installed in case. Valve body can not be in­ stalled if switch is in position.
(52) Install valve body as follows: (a) Start park rod into park pawl. If rod will not
slide past park pawl, pawl is engaged in park gear.
Rotate overdrive output shaft with socket to free
pawl and allow rod to engage.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a di­ agonal pattern to 12 N»m (105 in. lbs.) torque. Do
not overtighten valve body bolts. This could
result in distortion and cross leakage after in­ stallation..
(53) Install new filter on valve body. Tighten filter
screws to 4 N*m (35 in. lbs.).
(54) Adjust front and rear bands as follows: (a) Loosen band adjusting screw locknuts.
(b) Tighten each band adjusting screw to 5 Nnn
(72 in. lbs.) with torque wrench.
(c) Back off front band adjusting screw 2-1/2 turns.
(d) Back off rear band screw 4 turns.
(e) Tighten each adjusting screw locknut. Hold
adjusting screws with wrench to prevent turning
when tightening locknut. (55) Install seal on park/neutral position switch
(Fig. 162). Then install and tighten switch to 34 N«m
(25 ft. lbs.).
Fig.
162 Park/Neutral Position
Switch
Seal
Position
(56) Install magnet in oil pan. Magnet goes on
small protrusion at corner of pan. (57) Position new oil pan gasket on case and in­
stall oil pan. Tighten pan bolts to 17 N*m (13 ft. lbs.).
(58) Install new valve body manual shaft seal in
case (Fig. 163). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case.
Seat seal with 15/16 inch, deep well socket.
(59) Install throttle valve and shift selector levers
on valve body manual lever shaft. (60) Cap or cover transmission openings (cooler line
fittings, filler tube bore, etc.) to prevent dirt entry.
(61) Install torque converter. Use C-clamp or metal
strap to hold converter in place for installation. (62) Mount transmission on jack for installation in
vehicle.
(63) Apply dielectric grease to terminal pins of so­
lenoid case connector and neutral switch.

CAUTION:
The
transmission
cooler
and
lines
must
be
reverse
flushed
if
overhaul
corrected
a
malfunc­

tion
that
generated
sludge,
metal
particles,
or
clutch
friction
material.
The
torque
converter
should

also
be replaced if
contaminated
by the
same
mal­

function.
Debris and
residue
not
flushed
from
the
cooler
and
lines
will
flow
back
into
the
transmission
and
converter.
The
result
could
be a
repeat
failure

and
shop
comeback.

21
- 278
TRANSMISSION
0VERHAUL-4IRH

•
TRANSMISSION OWERHAUL-46RH

INDEX

page

Accumulator Overhaul
288
Front Clutch Overhaul
293

Front Servo
and
Band Overhaul
............
289

Oil Pump
and
Reaction Shaft Support Overhaul
. 289

Overdrive Piston
and
Retainer Service
286

Overhaul Service
Information
285

Overrunning Clutch Overhaul
286
Planetary Geartrain Overhaul
...............
297

TRANSMISSION
DISASSEMBLY
(1) Remove torque converter,
if not
previously
re­

moved. (2) Clean transmission exterior with steam
gun or

solvent. Wear safety goggles while cleaning trans­
mission. (3) Remove shift
and
throttle levers from shaft
of

valve body manual lever. (4) Remove bolts attaching overdrive unit
to
trans­
mission case
(Fig. 1).

Fig.
1
Removing
Overdrive Unit Attaching
Bolts

(5) Loosen overdrive unit.
Use pry
tool
to
start
overdrive unit
off
intermediate shaft
and
transmis­
sion case. Position
pry
tool between flange
on
over­
drive case
and
transmission rear servo boss
(Fig. 2).

(6) Work overdrive unit rearward
and off
transmis­
sion intermediate shaft
(Fig. 3).

(a)
If
overdrive unit does
not
require service,
in­

sert Alignment Tool 6227-2
in
overdrive unit over­
running clutch
and
planetary gear
to
maintain spline alignment
(Fig. 4). If
clutch
and
gear splines rotate
out of
alignment, overdrive unit
will have
to be
disassembled
in
order
to re­
align splines. (b)
If
overdrive unit does requires service, refer
to Overdrive unit Overhaul section.
page

Rear
Clutch Overhaul
295

Rear
Servo
and
Band Overhaul
. 289

Transmission
Assembly
...................
315

Transmission
Case
Cleaning
and
Inspection
. . . 285

Transmission
Disassembly
278
Valve
Body Cleaning
and
Inspection
308
Valve
Body Service
and
Adjustment
. 302
Fig.
2
Loosening
Overdrive Unit From
Transmission

J9121-209

Fig.
3
Removing
Overdrive Unit From
Transmission—46RH

(7) Remove thrust plate from overdrive piston
(Fig.

5). (8)
Remove overdrive piston from retainer
(Fig. 6).
(9)
Remove overdrive pistop thrust bearing
(Fig.

7).
(10) Mount transmission unit
on
Repair Stand
C-3750-B,
or
support transmission with wood blocks.

TRANSMISSION
OVERHAUL-46RH
21 - 279

SPECIAL

J9321-133

Fig.
4 Overdrive Spline Alignment Tool
Installation
>sPISTON THRUST PLATE (SELECT FIT)
W

OVERDRIVE PISTON
J9121-503

Fig.
5
Removing
Overdrive
Piston
Thrust
Plate—46RH
PISTON OVERDRIVE
PISTON
THRUST

BEARING

\

J9121-279

Fig.
7 Removing/Installing Overdrive Piston Thrust
Bearing
(11) Remove pump oil seal with Special Tool C-3861
(Fig. 8). Be sure to tighten tool threads completely into
seal before using puller bolt to withdraw seal.
J9321-182\>s

Fig.
8
Removing
Pump
Oil Seal—46RH (12) Remove oil pan bolts and remove pan (Fig. 9)
and gasket (Fig. 10). Oil pan magnet can be removed
or left in pan as needed (Fig. 11). Exercise care when
removing pan to avoid distorting or bending pan
flange.
PISTON
RETAINER
Fig.
6
Removing
Overdrive Piston—46RH
J9121-5
Fig.
9 Removing/Installing Oil Pan—46RH