DODGE TRUCK 1993 Service Repair Manual

21
• 300
TRANSMISSION
OVERHAUL-48RH

•

OUTPUT SHAFT DRIVING

SHELL

THRUST PLATE

J9121-69

Fig.
80 installing Rear
Annulus
Thrust Plate—46RH REAR

ANNULUS

GEAR
REAR

PLANETARY
GEAR
SUN
GEAR
OUTPUT
SHAFT

J9121-72

Fig.
83 installing Sun Gear And Driving
Shell—46RH
TAB

SLOTS
(3)
DRIVING

SHELL
REAR

PLANETARY
GEAR

J9121-70

Fig.
81 Installing Rear Planetary Gear—46RH
REAR

PLANETARY
GEAR
TABBED

THRUST
_

WASHER
^121-71
Fig.
82 Installing Rear Planetary Thrust

Washer-46RH

(12) Install front planetary and annulus gear as­
sembly (Fig. 87). Hold gears together and slide them
TABBED

THRUST

WASHER

J9121-73

Fig.
84 Installing Driving
Shell
Thrust
Washer-46RH
onto shaft. Be sure planetary pinions are seated on
sun gear and that planetary carrier is seated on out­
put shaft.
(13) Place geartrain in upright position. Rotate
gears to be sure all components are seated and prop­
erly assembled. Snap ring groove at forward end of
output shaft will be completely exposed when compo­
nents are assembled correctly.
(14) Install planetary snap ring in groove at end of
output shaft (Fig. 88). (15) Turn planetary geartrain over. Position wood
block under front end of output shaft and support
geartrain on shaft. Be sure all geartrain parts have
moved forward against planetary snap ring. This is important for accurate end play check.

•

TRANSMISSION
0WERHAUL-4SRH
21 - 301

Fig.
85 Installing Thrust
Washer
On Front Planetary
Gear-46RH

Fig.
86
Assembling
Front Planetary And
Annulus
Gears—46RH
(16) Check planetary geartrain end play with
feeler gauge (Fig. 89). Insert gauge between rear an­
nulus gear and shoulder on output shaft as shown.
End play should be 0.15 to 1.22 mm (0.006 to 0.048

in.).

(17) If end play is incorrect, install thinner/thicker
planetary snap ring as needed.
Fig.
87 Installing Front Planetary And
Annulus
Gear

Assembly—46RH

Fig.
88 Installing Planetary
Snap
Ring—46RH

21
- 302
TRANSMISSION
OVERHAUL-46RH

Fig.
89
Checking
Planetary
Geartrain
End
Play

VALVE
BODY
SERVICE
AND
ADJUSTMENT
VALVE BODY MAIN COMPONENT

DISASSEMBLY

CAUTION:
Do not
clamp
any
valve
body
component
in
a
vise.
This
practice
can
damage
the
component

resulting
in
unsatisfactory
operation
after
assembly

and
installation.
Remove
valves,
plugs
and
springs

with
a
pencil
magnet
Do not use
pliers
to
remove

any
of the
valves,
plugs
or
springs
and
do
not
force

any
of
the
components
out or
into
place.
The
valves

and
valve
body
housings
will be
damaged
if
force
is
used.
Tag
or
mark
the
valve
body
springs
for
refer­

ence
as
they
are
removed.
Do not
allow
them
to be­

come
intermixed.

(1) Remove boost valve cover
(Fig. 90).

(2) Remove boost valve retainer, valve spring
and

boost valve
(Fig. 91).
HOUSING
J932M26
•

Fig.
91
Boost
Valve
Components—46RH

DETENT
BALL AND
SPRING
HOUSING
J9321-121
Fig.
92
Securing
Detent
Ball
And
Spring
(4) Remove E-clip that secures throttle lever
in

manual lever
(Fig. 93).
J932M38

Fig.
93
Removing
Throttle
Lever
E-Clip-46RH (5) Lift
and
rotate manual lever
far
enough
to

clear detent housing.
Fig.
90
Boost
Valve
Cover
Location—46RH
(3) Secure detent ball
and
spring with Retainer
Tool 6583
(Fig. 92).

TRANSMISSION
0VERHAUL-46RH
21 - 303
(6) Remove retaining tool and remove detent ball
and spring (Fig. 94).
MANUAL

LEVER

DETENT

HOUSING

DETENT
BALL.

AND

SPRING
J9321-139

Fig.
94 Detent
Ball
And
Spring
Removal
(7) Remove washer at top of manual lever shaft.
Then lift manual lever and park rod assembly up­ ward and out of valve body (Fig. 95).
MANUAL

LEVER
AND

PARK ROD

ASSEMBLY
MANUAL

LEVER
WASHER

J9321-140
Fig.
95 Manual
Lever
Removal—46RH
(8) Remove throttle lever from valve body housing
(Fig. 96).

THROTTLE
LEVER

J932M41

Fig.
96
Throttle
Lever
Removal—46RH (9) Remove park rod E-clip and separate rod from
manual lever (Fig. 97).
MANUAL

LEVER

PARK
ROD
J9121-81

Fig.
97
Park
Rod Removal—46RH
(10) Remove screws attaching pressure adjusting
screw bracket to valve body and transfer plate. Hold
bracket firmly against spring tension while removing last screw.
(11) Remove adjusting screw bracket, line pressure
adjusting screw, pressure regulator spring and switch
valve spring (Fig. 98). Do not remove throttle
pressure adjusting screw from bracket and do
not disturb adjusting screw settings during re­
moval.
PRESSURE

REGULATOR

VALVE SPRING

SWITCH
VALVE

SPRING
LINE
PRESSURE

ADJUSTING
SCREW
ADJUSTING

SCREW

BRACKET
mm

J9121-512
Fig.
98 Adjusting
Screw
Bracket And
Spring

Removal—46RH
(12)
Remove solenoid connector from 3-4 accumula­
tor housing (Fig. 99). Note that connector is at­
tached to housing with shoulder-type screw. Keep this screw with accumulator housing to avoid losing it.
(13) Note routing of solenoid wires for assembly
reference (Fig. 100).

21
- 304
TRANSMISSION OVERHAUL-46RH

•

SOLENOID

CONNECTOR
3-4

ACCUMULATOR
HOUSING

a-J9321-143

Fig.
99
Solenoid
Connector
Position—46RH
SOLENOID
WIRES
(NOTE
WIRE

ROUTING)

J932M42

Fig.
100
Solenoid
Wire
Routing—46RH
(14) Remove screws attaching solenoid assembly
to

valve body lower housing
and
remove solenoid
and

connector assembly
(Fig. 101).
SOLENOID

ATTACHING
SCREWS
LOWER

HOUSING

SOLENOID
ASSEMBLY
J9321-144

Fig.
101
Solenoid
Assembly
Removal—46RH (15) Remove
3-4
accumulator housing attaching
screws
and
remove housing from valve body
(Fig.
102).

3-4

ACCUMULATOR
HOUSING HOUSING

ATTACHING
SCREWS
Fig.
102
Removing
3-4
Accumulator
Housing

(16) Remove following parts from valve body lower
housing:
3-4
shift valve
and
spring; pressure regula­
tor valve spring; clutch valve; clutch valve spring; and clutch valve plug
(Fig. 103).

LOWER

HOUSING
CLUTCH

VALVE
AND
SPRING
3-4

SHIFT

VALVE
AND

SPRING
CLUTCH

VALVE
PLUG
PRESSURE

REGULATOR
VALVE

SPRING
J9321-146

Fig.
103
Clutch
Valve
And 3-4
Shift
Valve
Locations—46RH

(17) Remove boost valve connecting tube
(Fig.

104).
Disengage tube from upper housing port first.
Then rock opposite
end of
tube back
and
forth
to

work
it out of
lower housing.

CAUTION:
Do not use
tools
to
loosen
or pry the

connecting
tube
out of the
valve
body
housings.
Loosen
and
remove
the
tube
by
hand only.

TRANSMISSION
OVERHAUL-46RH
21 - 305
BOOST
.VALVE TUBE LOWER
HOUSING
UPPER
HOUSING DISENGAGE
THIS END OF TUBE FIRST J9321-147

Fig.
104
Boost
Valve
Tube Removal—46RH (18) Turn valve body over so valve lower housing
is facing upward (Fig. 105). In this position, check
balls in upper housing will remain in place and not fall out when lower housing and transfer plate are
removed.
(19) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
105).
Note position of boost valve tube brace for
assembly reference.
LOWER
HOUSING VALVE
BODY
SCREWS (13)
~\L^ VALVE TUBE
BRACE J932M48

Fig.
105
Valve
Body
Screw
And Tube
Brace
Location—46RH

(20) Remove lower housing and overdrive separa­
tor plate from transfer plate (Fig. 106). (21) Remove transfer plate from upper housing
(Fig. 107). (22) Turn transfer plate over so upper housing sep­
arator plate is facing upward (Fig. 108). (23) Remove brace plate from lower housing sepa­
rator plate and transfer plate (Fig. 108).
(24) Remove upper housing separator plate from
transfer plate (Fig. 109). Note position of filter in separator plate for assembly reference.
(25) Remove rear clutch check ball from transfer
plate. Note check ball location for assembly ref- OVERDRIVE
SEPARATOR
PLATE TRANSFER
PLATE AND UPPER
HOUSING
LOWER
HOUSING J932M49

Fig.
106
Lower
Housing
Removal—46RH UPPER
HOUSING
TRANSFER PLATE

J932M52

Fig.
107
Removing
Transfer
Plate
From Upper
Housing—46RH

BRACE
J932M50 SEPARATOR TRANSFER
PLATE PLATE

Fig.
108
Brace
Plate
Removal—46RH
erence before removing it (Fig. 110).

21
- 306
TRANSMISSION
OVERHAUL-46RH

•

TRANSFER
UPPER

J9321-151

Fig.
109 Upper
Housing
Separator
Plate
Removal—RH

Fig.
110 Rear
Clutch
Check
Ball
Location—46RH
VALWE
BODY
UPPER
HOUSING

DISASSEMBLY

(1) Note location of check balls in valve body upper
housing (Fig. 111). Then remove one large and six smaller diameter check balls with magnet (total of 7
check balls are used).
(2) Remove E-clip that secure shuttle valve second­
ary spring on valve stem (Fig. 112).
(3) Remove governor plug and shuttle valve covers
(Fig. 113).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 113). (5) Remove boost valve retainer, spring and valve
if not previously removed. (6) Turn upper housing over and remove switch
valve, regulator valve and spring, and manual valve (Fig. 114). (7) Remove kickdown detent, kickdown valve, and
throttle valve and spring (Fig. 114). (8) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 114). Also remove shuttle valve primary spring if not removed in prior step.
SMALL

DIAMETER
CHECK

BALLS
(6)

LARGE
DIAMETER
CHECK

BALL
(1)
J932M54

Fig.
112 Shuttle
Valve
E-Clip
And
Secondary
Spring
Location
(9) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 115). (10) Remove limit valve housing. Then remove re­
tainer, spring, limit valve, and 2-3 throttle plug from limit valve housing (Fig. 115).
(11) Remove 1-2 shift control valve and spring
(Fig. 115). (12) Remove 1-2 shift valve and spring (Fig. 115).
(13) Remove 2-3 shift valve and spring from valve
body (Fig. 115). (14) Remove pressure plug cover (Fig. 115).
(15) Remove line pressure plug, sleeve, throttle
pressure plug and spring (Fig. 115).

TRANSMISSION
OVERHAUL-46RH 21 - 307
-156
Fig. 113 Shuttle And Boost Valve Components—46RH
Fig. 114 Control Valve Locations—46RH Upper Housing

21 - 308
TRANSMISSION OVERHAUL-46RH
•

UPPER
HOUSING
PLUG RETAINER
AND
VALVE
COVER SPRING COVER
J9321-157

Fig.
115 Shift Valves And
Pres
VALVE
BODY
LOWER
HOUSING

DISASSEMBLY
(FIG. 116)
(1) Remove timing valve cover.
(2) Remove 3-4 timing valve and spring.
(3) Remove 3-4 shuttle valve E-clip and remove
shuttle valve spring and plug.
(4) Remove 3-4 shift valve and spring. (5) Remove
converter clutch valve, spring and plug. (6) Remove converter clutch timing valve, retainer
and valve spring.
3-4
ACCUMULATOR HOUSING DISASSEMBLY
(FIG.
117)
(1) Remove end plate from housing.
(2) Remove piston spring. (3) Remove piston. Remove and discard piston

seals.

VALVE BODY CLEANING
AND
INSPECTION
The only serviceable valve body components are:
• solenoid and connector assembly
• solenoid gasket
• park rod and E-clip
• switch valve and spring
• pressure adjusting screw bracket
• throttle valve lever • manual lever
• manual shaft seal, washer, and E-clip e
Plugs—46RH
Upper
Housing

• fluid filter
• detent ball and spring The remaining valve body components are serviced
only as part of a complete valve body assembly. Clean the valve body components with a standard
parts cleaning 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. Lint from these materi­ als will stick to the valve body components. Lint
will interfere with valve operation and may clog
filters and 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 components 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 a sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-

TRANSMISSION
0VERHAUL-4IRH
21 - 309

LOWER HOUSING
3-4
SHUTTLE
3-4
ACCUMULATOR PISTON
3-4
ACCUMULATOR HOUSING
3-4
SHUTTLE VALVE
THROTTLE PLUG
TIMING VALVE

COVER
3-4 SHIFT
VALVE AND
SPRING
SPRING

RETAINER
CONVERTER CLUTCH TIMING VALVE AND SPRING
CONVERTER CLUTCH
SOLENOID SOLENOID
GASKET

OVERDRIVE

SEPARATOR
PLATE
J932M58

3^4 ACCUMULATOR
HOUSING
ACCUMULATOR PISTON
Fig.
116 Shift Valves
And
Springs—46RH
Lower
Housing
CAUTION: Many
of the
valves
and
plugs, such
as

the
throttle
valve,
shuttle
valve
plug,
1-2
shift
valve
and
1-2
governor
plug,
are
made
of
coated
alumi­
num
(Fig.
118).
Aluminum
components
are
identi­

fied
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.
This
practice
could
damage
the
special
coating
and
cause
the
valves
and
plugs
to

stick
and
bind. PISTON

SEAL

RING
PISTON

SPRING

END
PLATE
J9121-277

Fig.
117 3-4
Accumulator
Housing

Components—46RH
Inspect
the
valves
and
plugs
for
scratches, burrs,

nicks,
or
scores. Minor surface scratches
on
steel
valves
or
plugs
can be
removed with crocus cloth
but
do
not
round
off the
edges
of the
valve
or
plug

lands.
Maintaining sharpness
of
these edges
is vi­

tally important.
The
edges 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.

Check
the two
separator plates
for
distortion
or

damage
of any
kind. Inspect
the
upper housing,
lower housing,
3-4
accumulator housing,
and
transfer
face.
If
distortion
is
severe
or any
surfaces
are

heavily scored,
the
valve body will have
to be re­
placed.