DODGE TRUCK 1993 Service Repair Manual

21 - 290
TRANSMISSION OVERHAUL-46RH
•

REACTION SHAFT
SUPPORT GEAR
BORE

J932M76

Fig.
51 Reaction Shaft
Support
Removal—46RH
(6) Remove oil pump seal with Remover Tool

C-3981.
Discard seal after removal.
INSPECTING PUMP AND
SUPPORT
Clean pump and support components with solvent
and dry them with compressed air.
Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, severely
worn, or no longer hooked together.
PUMP BODY INNER
GEAR OUTER
GEAR
J932M77

Fig.
52
Pump
Gear Removal—46RH
Inspect the pump and support components. Replace
the pump or support if the seal ring grooves or ma­ chined surfaces are worn, scored, pitted, or damaged.
Replace the pump gears if pitted, worn chipped, or
damaged.
Fig.
53 Oil
Pump
And Reaction Shaft
Components—46RH

+

Fig.
55
Checking
Pump
Gear End Clearance

OIL
PUMP
BUSHING
REPLACEMENT
(FIG. 57} (1) Position pump housing on clean, smooth sur­
face with gear cavity facing down.
(2) Remove bushing with Tool Handle C-4171 and
Bushing Remover SP-3550.
TRANSMISSION
0VERHAUL-46RH
21 - 291
J8921-388

Fig.
56
Checking
Pump
Gear
Side
Clearances
(3) Assemble Tool Handle C-4171 and Bushing In­
staller SP-5118. (4) Place bushing on installer tool and start bush­
ing into shaft.
(5) Tap bushing into place until Installer Tool SP-
5118 bottoms in pump cavity. Keep tool and bushing
square with bore. Do not allow bushing to become
cocked during installation.
(6) Stake pump bushing in two places with blunt
punch. Remove burrs from stake points with knife
blade (Fig. 58).
Check the pump vent (Fig. 54). The vent must be
secure. Replace the pump body if the vent is cracked,
broken, or loose.
Inspect the pump bushing (Fig. 54). Then check the
reaction shaft support bushing. Replace either bush­ ing only if heavily worn, scored or damaged. It is not
necessary to replace the bushings unless they are ac­
tually damaged.
Install the gears in the pump body and measure
end clearance with a feeler gauge and straightedge (Fig. 55). Clearance should be 0.89 to 1.90 mm (0.0035 to 0.0075 in.).
Measure side clearances with feeler gauge (Fig.

56).
Clearance between gear teeth and between outer
gear and pump body should be 0.89 to 1.90 mm (0.0035 to 0.0075 in.).

PUMP

21
- 292
TRANSMISSION
OVERHAUL-46RH

•

SPECIAL
TOOL

C-4171
BUSHING
REMOVAL
PUMP HOUSING

SPECIAL
TOOL

C-4171
SPECIAL
TOOL

SP-3550

BUSHING

SPECIAL
TOOL

SP-5118
J9221-244

Fig. 57 Replacing Oil Pump Bushing
mm
Fig. 58 Staking-Debum'ng Oil Pump Bushing
REPLACING
REACTION SHAFT SUPPORT

BUSHING
(FIG. 59)
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushing Remover
SP-5301.
(2) Hold cup tool firmly against reaction shaft.
Thread remover tool into bushing as far as possible
by hand.
(3) Using wrench, thread remover tool an addi­
tional 3-4 turns into bushing to firmly engage tool.
(4) Tighten tool hex nut against cup tool to pull
bushing from shaft. Clean all chips from shaft and support after bushing removal.
(5) Place reaction shaft support upright on a clean,
smooth surface.
(6) Assemble Bushing Installer Tools C-4171 and
SP-5302. Then slide new bushing onto installer tool. (7) Start bushing in shaft. Tap bushing into shaft
until installer tool bottoms against support flange. (8) Clean reaction shaft support thoroughly after
bushing replacement (to remove any chips).
SPECIAL

TOOL

SP-1191
SPECIAL

TOOL

C-4171

SPECIAL
TOOL

SP-5302

BUSHING BUSHING

X
REACTION SHAFT
BUSHING
REMOVAL BUSHING
INSTALLATION
J9221-245

Fig. 59 Reaction Shaft Bushing Replacement—46RH

ASSEMBLING
OIL
PUMP
AND
REACTION SHAFT SUPPORT

(1) Lubricate pump gears with transmission fluid
and install them in pump body.
(2) Install thrust washer on reaction shaft support

hub.
Lubricate washer with petroleum jelly or trans­ mission fluid before installation.
(3) If reaction shaft seal rings are being replaced,
install new seal rings on support hub. Lubricate seal
rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are
securely hooked together.

CAUTION:
The
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.

(4) Align and install reaction shaft support on
pump body.
(5)
Install bolts attaching reaction shaft support to
pump. Tighten bolts to 20 N»m (175 in. lbs.) torque. (6) Install new pump seal with Seal Installer
C-3860-A (Fig. 60). Use hammer or mallet to tap seal
into place.
(7) Install new O-ring on pump body. Lubricate oil
seal and O-ring with petroleum jelly.

TRANSMISSION
0VERHAUL-46RH
21 - 293
(4) Remove clutch piston springs. Note number
and position of piston springs for assembly
ref­

erence. (5) Remove clutch piston from retainer with a
twisting motion. (6) Remove and discard clutch piston inner and
outer seals.

FRONT CLUTCH INSPECTION
Clean and inspect the front clutch components. Re­
place the clutch discs if warped, worn, scored, burned or charred, the lugs are damaged, or if the facing is
flaking off. Replace the steel plates and reaction
plate if heavily scored, warped, or broken. Be sure
the driving lugs on the discs and plate are also in
good condition. The lugs must not be bent, cracked or
damaged in any way.
Replace the piston springs and spring retainer if ei­
ther are distorted, warped or broken.
Check the lug grooves in the clutch piston retainer.
The steel plates should slide freely in the slots. Re­
place the piston retainer if the grooves are worn or damaged. Also check action of the check ball in the
piston retainer. The ball must move freely and not stick.
Replace the retainer bushing if worn, scored, or
there is any doubt 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 the clutch piston check ball. The ball should
be securely in place. Replace the piston if the ball is missing, or seized in place.
INNER
CLUTCH CLUTCH PISTON CLUTCH CLUTCH
Fig.
61
46RH
Front
Clutch
Components
(3-Disc
Clutch
Shown)

SPECIAL

TOOL

C-3860-A

PUMP

SEAL
PUMP

BODY

J932M79

Fig.
60 Oil
Pump Seal
Installation—46RH (8) Set pump assembly aside for installation dur­
ing transmission assembly.

FRONT
CLUTCH
OVERHAUL

FRONT CLUTCH
DISASSEMBLY
(1) Remove waved snap ring and remove reaction
plate, clutch plates and clutch discs (Fig. 61). Note
number of plates and discs in clutch pack for as­ sembly reference. Some models use 3 discs,
while some may have 4 discs.
(2) Compress clutch piston retainer and piston
springs with Compressor Tool C-3863-A (Fig. 62).
(3) Remove retainer snap ring and remove com­
pressor tool.

21
- 294
TRANSMISSION
OVERHAUL-46RH

SPECIAL TOOL
C-3863-A

RH290
Fig.
62
Removing
Front
Clutch
Spring
Retainer
Snap Ring FRONT
CLUTCH
RETAINER
BUSHING
REPLACEMENT (FIG. 63)
(1) Assemble Tool Handle C-4171 and Bushing Re­
mover SP-3629.
(2) Insert remover tool in bushing and drive bush­
ing straight out of clutch retainer.
(3) Mount Bushing Installer SP-5511 on tool han­

dle.
(4) Slide new bushing onto installer tool and start
bushing into retainer.
(5) Tap new bushing into place until installer tool
bottoms against clutch retainer.
(6) Remove installer tools and clean retainer thor­
oughly.
ASSEMBLING
FRONT
CLUTCH (1) Soak clutch discs in transmission fluid. Lubri­
cate remaining clutch components with transmission
fluid. Retainer bushing can be lubricated with petro­
leum jelly if desired.
(2) Install new inner and outer seals on clutch pis­
ton. Be sure seal lips face interior of retainer. (3) Lubricate new inner and outer piston seals
with Ru-Glyde, or Door Eze.
(4) Install clutch piston in retainer. Use twisting
motion to seat piston in retainer. Do not force pis­
ton straight in. This could fold seals over caus­ ing leakage and clutch slip. (5) Install and position clutch piston springs as
shown in Figure 64.
(6) Install spring retainer on top of piston springs. (7) Compress spring retainer and piston springs
with Compressor Tool C-3863-A.
SPECIAL

TOOL-

C-4171

FRONT CLUTCH
RETAINER
vsvv

n

HI
BUSHING

HI

REMOVAL
SPECIAL

TOOL

SP-3629
SPECIAL

TOOL

C-4171
SPECIAL

TOOL

SP-5511
J9221-247

Fig.
63 Front
Clutch
Retainer
Bushing

Replacement—46RH

9
SPRING CLUTCH

11
SPRING CLUTCH
13 SPRING CLUTCH
J9221-260

Fig.
64 Front
Clutch
Spring
Location
(8) Install spring retainer snap ring and remove
compressor tool.
(9) Install clutch plates and discs. Install steel
plate followed by clutch disc until all plates and discs

•

TRANSMISSION
OVERHAUL-46RH
21 - 295 are installed. Install same number of discs and
plates as removed during disassembly. Some
models require 3 plates and discs. Others re­ quire 4 plates and discs.
(10) Install reaction plate and waved snap ring.
(11) Check clutch pack clearance with feeler gauge
as follows (Fig. 65):
• On 3 disc clutch, clearance between waved spring
and pressure plate should 1.78 - 3.28 mm (0.070 -
0.129 in.).
• On 4 disc clutch, clearance between waved spring
and pressure plate should be 2.08 to 3.83 mm (0.082
to 0.151 in.). • If clearance Is Incorrect, clutch plates, clutch

discs,
snap ring and pressure plate will have to
be changed. Clutch pack waved snap ring is not select fit.

FEELER
GAUGE
RH288

Fig.
65
Measuring
Front
Clutch
Pack
Clearance

REAR
CLUTCH OVERHAUL

REAR
CLUTCH DISASSEMBLY
(FIG. 66) (1) Remove clutch pack select fit snap ring.
(2) Remove reaction plate and remove clutch plates
and discs.
(3) Remove pressure plate, wave spring, spacer
ring and piston spring from clutch retainer.
(4) Remove clutch piston from piston retainer with
a twisting motion. (5) Remove input shaft thrust washer, if washer
remained in piston retainer hub during removal.
(6) Remove seals from clutch piston. Discard seals
after removal.
REAR
CLUTCH INSPECTION

Clean the clutch components with solvent and dry
them with compressed air. Check condition of the input shaft seal rings. It is
not necessary to remove or replace rings unless they
are broken, cracked, or no longer securely hooked to­ gether.
Inspect the input shaft splines and machined sur­

faces.
Very minor nicks or scratches can be smoothed off with crocus cloth, replace the shaft if the splines
are damaged, or any of the machined surfaces are se­
verely scored.
Replace the clutch discs if warped, worn, scored,
burned/charred, the lugs are damaged, or if the fac­ ing is flaking off.
Replace the steel plates and the pressure plate if
heavily scored, warped, or broken. Be sure the driv­ ing lugs on the discs and plates are also in good con­
dition. 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
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.
Also check action of the retainer check ball. The ball must move freely and not stick.
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 damaged.
Check thrust washer condition. Washer thickness
should be 1.55 to 1.60 mm (0.061 to 0.063 in.). Re­
place the washer if worn or damaged.
Check condition of the two seal rings on the input
shaft and the single seal ring on the piston retainer

hub.
Replace the seal rings only if severely worn, cracked, or if they can no longer be hooked together.

INPUT SHAFT REPLACEMENT
If the input shaft must be replaced, first remove
the retaining ring that secures the shaft in the pis­
ton retainer hub. Then press the old shaft out of the retainer with a shop press.
Lubricate the splines of the new shaft with petro­
leum jelly or ATF Plus. Then align the shaft in the
piston retainer and carefully press it into place. Do not allow the shaft to become cocked during installa­
tion. The retainer can be cracked if misalignment oc­
curs.

Install the shaft retaining ring after pressing the

.
shaft into place. Be sure the ring is fully seated be­ fore proceeding with clutch assembly.

21
- 296
TRANSMISSION OVERHAUL-46RH
Fig.
66 Rear
Clutch
REAR
CLUTCH
ASSEMBLY

(1) Soak clutch discs in transmission fluid. Lubri­
cate remaining clutch components with transmission
fluid. Clutch retainer bushing can be lubricated with
petroleum jelly if desired. (2) Install new seals on clutch piston. Lubricate
piston seals with Ru-Glyde or petroleum jelly to ease installation. Be sure seal lips face input shaft.
(3) Install clutch piston in piston retainer. Use
twisting motion to seat piston in retainer. Do not
push piston straight in. This could distort seals
causing leakage and clutch slip.
(4) Assemble piston retainer and clutch retainer.
(5) Support clutch retainer with wood blocks, or in­
sert input shaft through predrilled, appropriate di­ ameter hole in workbench. Clutch pack components
are easier to install if both retainers are properly
supported.
(6) Install piston spring in clutch retainer. Con­
cave side of spring faces upward and away from
clutch piston. Convex side faces downward toward
piston.
(7) Install spacer ring on top of piston spring.
(8) Install wave spring on top of spacer ring. Then
seat wave spring in retainer groove. If wave spring will not seat properly, spacer ring has probably shifted over and into wave spring groove in re­
tainer. Use small screwdriver to realign spacer ring if necessary.
(9) Install inner pressure plate in clutch retainer. (10) Install first clutch disc followed by steel plate
until all discs and plates are installed.
(11) Install reaction plate on top of last clutch disc.
Components—46RH

(12) Install selective snap ring to secure clutch
pack in retainer. (13) Install new seal rings on input shaft if neces­
sary (Fig. 67). Be very sure ring ends are all securely
hooked together before proceeding.

Fig.
67 Input Shaft
Seal
Ring
Locations

(14) Check clutch pack clearance with feeler gauge
(Fig. 68). Clearance should be 0.63 to 1.14 mm (0.025
to 0.045 in.).
(15) If clutch pack clearance is incorrect, clutch
pack snap ring, reaction plate, or clutch pack may
have to be replaced.
(16) Install thrust washer on piston retainer hub
(Fig. 66). Use petroleum jelly to hold thrust washer
in place.

•
J9321-167

Fig.
68 Measuring Rear Clutch Pack Clearance

PLANETARY
GEARTRAIN
OVERHAUL
PLANETARY
GEARTRAIN
DISASSEMBLY

(1) Remove planetary snap ring from intermediate
shaft (Fig. 69). Retain snap ring if in good condition.
It is reusable.
Fig.
69
Removing
Planetary
Snap
Ring—46RH

(2) Remove front planetary gear and front annulus
gear as assembly (Fig. 70). (3) Remove front planetary gear and thrust washer
from front annulus gear (Fig. 71). Note thrust
washer position for assembly reference. (4) Remove tabbed thrust washer from driving
shell (Fig. 72). Note washer position for assembly
ref­

erence.
(5) Remove sun gear and driving shell as assembly
(Fig. 73). (6) Remove tabbed thrust washer from rear plane­
tary gear (Fig. 74). Note washer position on gear for
assembly reference.
(7) Remove rear planetary gear and rear annulus
gear from intermediate shaft (Fig. 75).
(8) Remove thrust plate from rear annulus gear
(Fig. 76).
TRANSMISSION
0VERHAUL-46RH
21 - 297

Fig.
71
Disassembling
Front Planetary And
Annulus
Gears—46RH
Intermediate
Shaft
And
Geartrain
Inspection

Clean the intermediate shaft and planetary compo­
nents (Fig. 77) in parts cleaning solvent and dry
them with compressed air.
Inspect the planetary gear sets and annulus gears.
The pinion gears, pinion shafts, pinion washers and shaft retaining pins are all serviceable and can be re­
placed if worn or damaged. However, if a pinion car­
rier is damaged, the entire planetary gear set must
be replaced as an assembly.
Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the planetary thrust plates and the tabbed thrust wash­
ers if cracked, scored or worn.

21
- 298
TRANSMISSION
0¥IRHAUL-48RH

•

Fig.
72 Driving Shell Thrust Washer Removal—46RH
INTERMEDIATE SHAFT
Fig.
73 Sun Gear And Driving Shell Assembly
Removal—46RH

SUN
REAR

SHELL
J932M72

Fig.
74 Rear Planetary Thrust
Washer
Removal—46RH
Inspect the machined surfaces of the intermediate
shaft. Be sure the oil passages are open and clear.
Replace the shaft if scored, pitted, or damaged.
INTERMEDIATE REAR REAR
SHAFT ANNULUS PLANETARY

J932M73

Fig.
75 Rear Planetary And Annulus Gear Removal—46RH

REAR
J9321-174

Fig.
76 Rear Annulus Thrust Plate Removal—46RH
Inspect the sun gear and driving shell (Fig. 77). If
either component is worn or damaged, remove the sun gear rear retaining ring and separate the sun
gear and thrust plate from the driving shell. Then
replace the necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as an assembly if the bushings are scored or worn. The
sun gear bushings are not serviceable. Replace the
thrust plate if worn, or severely scored. Replace the driving shell if distorted, cracked, or damaged in any
way.
PLANETARY GEARTRAIN ASSEMBLY AND
ADJUSTMENT
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly to lubricate output shaft bushing surfaces, thrust washers and thrust plates.

(2)
Install front snap ring on sun gear and install
gear in driving shell. Then install thrust plate over sun gear and against rear side of driving shell (Fig.

•

TRANSMISSION
QVERHAUL-46RH
21 - 299

Fig.
77 Planetary
Geartrain
Components—46
RH 78).
Install rear snap ring to secure sun gear and
thrust plate in driving shell. J932M75

Fig.
78 Sun Gear Installation—46RH (3) Install rear annulus gear on intermediate shaft
(Fig. 79).
(4) Install thrust plate in annulus gear (Fig. 80).
Be sure plate is seated on shaft splines and against gear.
(5) Install rear planetary gear in rear annulus
gear (Fig. 81). Be sure planetary carrier is seated
against annulus gear.
(6) Install tabbed thrust washer on front face of
rear planetary gear (Fig. 82). Seat washer tabs in
matching slots in face of gear carrier. Use extra pe­
troleum jelly to hold washer in place if desired.
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
Fig.
79 Installing Rear
Annulus
Gear On

Intermediate
Shaft—46RH (8) Install sun gear and driving shell on output
shaft (Fig. 83). Seat shell against rear planetary
gear. Verify that thrust washer on planetary gear
was not displaced during installation.
(9) Install tabbed thrust washer in driving shell
(Fig. 84). be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
washer in place if desired.
(10) Install tabbed thrust washer on front plane­
tary gear (Fig. 85). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
(11) Install front annulus gear over and onto front
planetary gear (Fig. 86). Be sure gears are fully
meshed and seated.