DODGE TRUCK 1993 Service Repair Manual

21
- 360
NP241
TRANSFER CASE

• cone with a minimum of wobble. Also check the syn­
chronizer struts for wear or damage.
Inspect all gear teeth for excessive wear or damage
and check all gear splines for burrs, nicks, wear, or
damage. Remove minor nicks or scratches with an oil stone. Replace any part exhibiting excessive wear or
damage.
Inspect all snap rings and thrust washers for exces­
sive wear, distortion or damage. Replace worn or
damaged parts. Inspect the two case halves for cracks, porosity,
damaged mating surfaces, stripped bolt threads, or
distortion. Replace either case half if necessary.
Inspect condition of all needle, roller, ball, and
thrust bearings in the front and rear case halves and
the input gear. Also check condition of the bearing
bores in both cases and in the input gear, rear output shaft, side gear, and rear retainer. Replace any com­
ponent exhibiting excessive wear or damage.
If the case or input gear bearings require replace­
ment, refer to the Transfer Case Bearing Replace­
ment procedures.

TRANSFER CASE BEARING REPLACEMENT

CAUTION:
Most
of the transfer
case
bearing
bores

contain
oil feed
holes.
Be
sure
replacement bear­
ings
do not
block
these feed
holes.

DRIVE SPROCKET BEARING REPLACEMENT (1) Remove both drive sprocket bearings simulta­
neously using a shop press, Tool Handle C-4171 and
Remover/Installer Tool C-4697-1 (Fig. 19). (2) Clean sprocket bearing bore after removing old
bearings. (3) Before proceeding, note that sprocket bearings
are positioned differently (Fig. 20). Front bearing is
installed flush with end of bore. However, rear bear­
ing is recessed slightly. Be sure to install bearings as
shown in Figure 20.
Fig.
19
Removing
Drive
Sprocket
Bearings
(4) Install new sprocket bearings one at a time
starting with front bearing. (a) Press front bearing flush with end of bore as
shown (Fig. 20). (b) Press rear bearing into sprocket until bearing
is 4.6 mm (11/64 in.) below edge of bore.

RR21F32
Fig.
20 Drive
Sprocket
Bearing
Installation

MAINSHAFT PILOT BEARING REPLACEMENT The mainshaft pilot bearing is located in the input
shaft. The bearing is removed from the shaft bore
with Remover Tool MD-998346 and two appropriate size backup wrenches (Fig. 21).
The new bearing is installed with Tool Handle
C-4171 and Installer
5065
(Fig. 22).
A shop press is recommended to press the bearing
into place. The bearing is seated when the installer
tool contacts the input shaft.
REPLACING MAINSHAFT REAR (OUTPUT)
BEARING The mainshaft rear (output) bearing is located in
the rear retainer. The seal must be removed before
the bearing can be replaced. (1) Remove seal with Remover Tool C-4613 (Fig.

23).

•

NP241 TRANSFER
CASE
21 - 361

Fig.
21
Removing
Mainshaft Pilot Bearing
Fig.
22 Installing Mainshaft Pilot Bearing (2) Remove bearing with Tool Handle C-4171 and
Remover C-4610 (Fig. 24).
(3) Clean bearing bore thoroughly.
(4) Install new bearing with Handle C-4171 and
Installer C-4609 (Fig. 25).
(5) Install new seal in rear retainer.

FRONT
OUTPUT
SHAFT
FRONT
BEARING
REPLACEMENT
(1) Remove bearing from front case bore with Tool
Handle C-4171, Remover C-4610 and a shop press (Fig. 26).
(2) Clean bearing bore thoroughly.
(3) Install new bearing with Tool C-4210, Handle
C-4171 and a shop press (Fig. 27).

FRONT
OUTPUT
SHAFT
REAR BEARING
REPLACEMENT
(1) Remove bearing from rear case bore with Re­
mover Tools L-4518-1 and L-4454-1 (Fig. 28).
(2) Clean bearing bore thoroughly.
Fig.
23
Removing
Rear Retainer
Seal

Fig.
24
Removing
Mainshaft Rear (Output) Bearing (3) Install new bearing with Handle C-4171 and
Installer C-4608 (Fig. 29).

TRANSFER
CASE
ASSEMBLY
(1) Lubricate transfer case components with auto­
matic transmission fluid during assembly. (2) If transfer case bearings were replaced, verify
that new bearings do not block any oil feed holes. (3) Assemble input gear, thrust washer and low
range gear. Be sure low range snap ring is fully seated. (4) Install input and low range gear assembly in
front case. Secure input gear with snap ring (Fig.
11).
(5) Install shift sector and new sector shaft seals.
Install range lever on sector shaft and tighten lever
locknut to 30 N*m (22 ft. lbs.) torque. (6) Install range fork and hub (Fig. 9).

21
- 3S2

NP241
TRANSFER CASE

•
Fig. 26 Removing Front Output Shaft Front Bearing Fig. 27 installing Front Output Shaft Front Bearing (7) Install front output shaft in case (Fig. 8). Fig. 28 Removing Front Output Shaft Rear Bearing
Fig. 29 Installing Front Output Shaft Rear Bearing (8) Assemble mainshaft, stop ring, synchronizer
and mainshaft drive sprocket.
(9) Insert mode fork in synchronizer sleeve. Then
install mainshaft and fork as assembly. Be sure shift
rail is aligned in range fork and is seated in case

bore.
(10) Install drive chain and front shaft sprocket
(Fig. 7).
(11) Install snap ring that secures driven sprocket
to front output shaft (Fig. 6).
(12) Install detent plunger, spring and plug (Fig.

14).
Replace O-ring on plug if necessary. Do not re­
use old O-ring if damaged. Tighten plug to 21 N»m (16 ft. lbs.) torque.
(13) Install mode spring on shift rail (Fig. 5).
(14) Install oil pump, pickup tube and screen in
rear case.
(15) Apply 3 mm (1/8 in.) wide bead of Mopar gas­
ket maker, silicone adhesive/sealer, or Loctite 515 to front case sealing surface.

NP241
TRANSFER CASE
21 - 363
(16) Align and install rear case on front case. In­
stall and tighten rear case-to-front case bolts to 27-34
Nnn (20-25 ft. lbs.). (17) Install lower snap ring on mainshaft (Fig. 2).
(18) Install speedometer gear and upper snap ring
(Fig. 1).
(19) Install new seals in retainers if necessary.
(20) Apply 3 mm (1/8 in.) wide bead of Mopar gas­
ket maker, silicone adhesive/sealer, Loctite 518, or
Loctite 573 to sealing surface of rear retainer. Then install retainer and tighten retainer bolts to 31 Nnn
(23 ft. lbs.).
(21) Install yokes, seal washers and retaining nuts.
Tighten yoke nuts to 176-271 Nnn (130-200 ft. lbs.)
torque.
(22) Install vacuum switch. Tighten switch to 27
Nnn (20 ft. lbs.). (23) Fill transfer case with Mopar ATF Plus, type
7176 transmission fluid.

21 - 364
TRANSMISSION/TRANSFER
CASE
SPECIFICATIONS
•

AUTOMATIC TRANSMISSION
GENERAL SPECIFICATIONS

TRANSMISSION
MODEL
32RHI42RH
'36RH/37RHI46RH

Oil Pump Clearances (all)
0.089-0.190
mm

(0.0035-0.0075
in)
0.089-0.190
mm

(0.0035-0.0075
in)
Planetary End Play
0.127-1.22
mm

(0.005-0.048
in)
0.15-1.22
mm

(0.006-0.048
in)
Input Shaft End Play
0.56-2.31
mm

(0.022-0.091
in)
0.86-2.13
mm

(0.034-0.084
in)
Clutch Pack Clearance: Front Clutch - 3
Disc

Front Clutch - 4
Disc

Front Clutch - 5
Disc

Rear Clutch - 3
Disc

Rear Clutch - 4
Disc
1.88-3.17
mm

(0.074-0.125
in)
1.70-3.40
mm

(0.067-0.134
in)

1.90-3.86
mm

(0.075-0.152
in)

0.81-1.40
mm

(0.032-0.055
in)

0.81-1.40
mm

(0.032-0.055
in)
1.78-3.28
mm

(0.070-0.129
in)
2.08-3.83
mm

(0.082-0.151
in)

0.64-1.14
mm

(0.025-0.045
in)
Clutch
Disc
Usage:

Front Clutch
Rear Clutch
Overdrive Clutch (Gas)
Overdrive Clutch (Diesel) Direct Clutch 32RH
42RH 36RH/37 RH 46RH
Clutch
Disc
Usage:

Front Clutch
Rear Clutch
Overdrive Clutch (Gas)
Overdrive Clutch (Diesel) Direct Clutch 4
4
4
4 4
6 3/4
4 3/4
4
4

5
8
Front Clutch Spring
Usage
1 1
9
9/11

Band
Adjustments:
(backed off from 72 in. lbs.) Front
Band

Rear
Band
2Vi
4 2Yi
4 214

2
Th
2
Recommended Fluid (all)
MOPAR
ATF
Plus,
Type 7176 Automatic Transmission Fluid

J9321-210

32RH/36RH/37RH
SPACER/THRUST
PLATE/SNAP
RING
SPECIFICATIONS
TRANSMISSION
MODEL

COMPONENT
32RH 36RH/37RH
Front Clutch Thrust Washer
(on reaction shaft
support
hub) .061 in.
.061 in
.084 in
.102 in
Rear Clutch Thrust Washer
(on clutch
retainer)
.061 in
.061 in
Output Shaft Thrust Plate (on Output shaft pilot hub)
.060-.063
in

.060-.063
in
Output Shaft Thrust Washer (in
rear
clutch hub)
.052-.054
in

.068-.070
in
.083-085
in
.068-.070
in
Rear Clutch Pack
Snap
Ring
.068 in
.060 in
.076 in
.098 in .060 - .062 in
.074 - .076 in
.088 - .090 in .106 - .108 in
Planetary Geartrain
Snap
Ring

(At
front
end of output shaft) .040 - .044 in
.062 - .066 in .082 - .086 in .048 - .052 in
.055 - .059 in .062 - .066 in
J922M42
TRANSMISSION/TRANSFER
CASE
SPECIFICATIONS

•

TRANSMISSION/TRANSFER CASE SPECIFICATIONS
21 - 365
411H

mm

Front Clutch Thrust Washer
(on reaction shaft support
hub)
.016
in.

.061
in.

.084
in.

.102
in.

Rear Clutch Thrust Washer
(on clutch retainer) .061
in.

.061
in.

Intermediate Shaft Thrust Plate
(on shaft pilot
hub)
.060-.063
in.

.060-.063
in.

Output Shaft Thrust Washer (in rear clutch
hub)
.068-.070
in.

.052-.054
in.

.068-.070
in.

.083-.085
in.

Rear Clutch
Pack
Snap Ring .060
in.

.076
in.

.098
in.
.060
in.

.074
in.

Planetary Geartrain Snap Ring
(at front
end of
intermediate shaft) .062
in.

.074
in.
.055-059
in.

.062-.066
in.

Overdrive Piston Thrust Plate Thrust plate
and
spacer
are
select
fit
components. Refer
to
size charts
and

selection procedures
in
"Overdrive Unit
Assembly
and
Adjustment."
Intermediate Shaft Spacer
Thrust plate
and
spacer
are
select
fit

components. Refer
to
size charts
and

selection procedures
in
"Overdrive Unit
Assembly
and
Adjustment."

J9221-143

AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONS (32RH/36RH/37RH)

Overdrive Clutch
Fourth
Gear Only
Pressure
should be
within
21
kPa
(3
psi)
of
line
pressure

Line
Pressure

(at
accumulator)
Closed
Throttle
1000 rpm and above
372-414
kPa
(54-60
psi)

648
kPa
(94 psi)

Front
Servo
Third
Gear Only No
more than 21 kPa
(3
psi) lower than line
pressure.

Rear
Servo 1 Range

R
Range No
more than 21 kPa
(3
psi) lower than line
pressure.
1103 kPa
(160
psi)
at
idle,

builds
to
1862 kPa (270
psi)
at
1600 rpm.
Governor
D
Range
Closed
Throttle
Pressure
should
respond smoothly to changes in mph
and
return to
0-7
kPa
(0-114
psi)
when stopped
with
transmission
in D,
1,
2.
Pmmmf®
mb&wm
7
kPm
(1
Va
psi)

at
standstill
will
prmnf transmission from drnwrnhlfflmg*
J9121-524
42RH/46RH SPACER/THRUST PLATE/SNAP RING SPECIFICATIONS

21 • 366
TRANSMISSION/TRANSFER
CASE
SPECIFICATIONS
•
Overdrive Clutch
Fourth Gear Only Pressure should be
469-496
kPa
(68-72
psi) with closed throttle and increase to

620-896
kPa
(90-130
psi) at 1/2 to 3/4 throttle.
Line Pressure
(at accumulator) Closed Throttle

1000
rpm and above
372-414
kPa
(54-60
psi)
648 kPa (94 psi)
Front Servo Third Gear Only No more than
21
kPa (3 psi) lower than line pressure.
Rear Servo
1
Range
R Range No more then
21
kPa (3 psi) lower than line pressure. 1103 kPa (160 psi) at idle,
builds to 1862 kPa (270 psi) at 1600 rpm.
Governor D Range
Closed Throttle Pressure should respond smoothly to changes in mph and return to 0-7 kPa
(0-1
Vi

psi) when stopped with transmission in D,
1,
2. Pressure
above
7
kPa
(IV2
psi)
at
standstill
will
prevent
transmission
from
downshifting.

J9321-192

AUTOMATIC
TRANSMISSION
TORQUE
SPECIFICATIONS

DESCRIPTION TORQUE DESCRIPTION TORQUE

Cooler Line Fittings 18 N-m (13 ft. lbs.)
Converter Bolts: 9.5 in.,
3-lug
converter 54 N-m (40 ft. lbs.
9.5 in., 4-lug converter 74 N-m (55 ft. lbs. 10.0 in., 4-lug converter 74 N-m (55 ft. lbs.
10.75 in., 4-lug converter 31 N-m (270 in. lbs.
Crossmember Bolts/Nuts 68 N-m (50 ft. lbs. Driveplate Bolts 75 N-m (55 ft. lbs.
Extension Housing Bolts 43 N-m (32 ft. lbs.
Front Band Reaction Pin Access Plug 17 N-m (13 ft. lbs.
Front Band Adjusting Screw Locknut 34 N-m (25 ft. lbs.
Governor Body-to-Park Gear Bolts 11 N-m (8 ft. lbs.
Lockup Module Screws 4 N-m (35 in. lbs.
Neutral Switch 34 N-m (25 ft. lbs.
Oil Filter Screws 4 N-m (35 in. lbs.
Oil Pan Bolt 17 N-m (13 ft. lbs.
Oil Pump Bolt 20 N-m (15 ft. lbs.
Overrunning Clutch Cam Set Screw (36RH/46RH) 5 N-m (40 in. lbs. Overrunning Clutch Cam Bolts 17 N-m (150 in. lbs.
Overdrive Compounder-to- Transmission Case Bolts 34 N-m (25 ft. lbs.
Overdrive Piston Retainer Bolts (42RH/46RH) 17 N-m (150 in. lbs.
Pressure Test Port Plugs 14 N-m (10 ft. lbs.
Propeller Shaft Clamp Bolts 19 N-m (170 in. lbs.
Reaction Shaft Support Bolts 20 N-m (15 ft. lbs.
Rear
Band
Adjusting Screw Locknut 41 N-m (30 ft. lbs.
Rear Mount Bolts/Nuts 68 N-m (50 ft. lbs.
Rear Support Bolts (32RH/36RH) 17 N-m (150 in. lbs.
Solenoid Wiring Connector Screw 17 N-m (13 ft. lbs.
Solenoid-to-Transfer Plate Screw 4 N-m (35 in. lbs.
Speedometer Adapter Bolt 11 N-m (8 ft. lbs.
Valve Body Housing Screws 4 N-m (35 in. lbs.
Valve Body-to-Case Bolts 12 N-m (100 in. lbs.

J9221-157

AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONS (42RH/46RH)

•
TRANSMISSION/TRANSFER
CASE
SPECIFICATIONS
21 - 367

DESCRIPTION

TORQUE

Backup Light Switch 22-34 N-m (193-300 in.
lbs.)

Countershaft Bearing Plate Bolts 19-26 N-m (170-230 in.
lbs.)

Fifth Gear Nut 339-475 N-m (250-350
ft. lbs.)

Drain
and
Fill Plugs 34-47 N-m (25-35
ft. lbs.)

Front Bearing Retainer Bolts 27-34 N-m (235-305 in.
lbs.)

Mainshaft Bearing Plate Bolts 19-26 N-m (170-230 in.
lbs.)
PTO
Cover Bolts 27-54 N-rn (20-40
ft.
lbs.)

Extension/Adapter Housing Bolts 41-68 N-m (30-50
ft.
lbs.)

Reverse Inhibitor Screws
8-14
N-m (75-115 in.
lbs.)

Shift Cover Bolts 27-31 N-m (216-276 in.
lbs.)

J9221-12
DESCRIPTION

TORQUE

Bearing Preload

Case
Bolts
Distance
Sensor
Coupling
Nut

Detent
Bolt

Drain/Fill
Plugs

Front/Rear Yoke Nuts Indicator Switch

Range
Lever
Locknut..
Rear
Retainer
Bolts
...

Speedometer Driven Gear
Nut

Transfer
Case
Mounting
Nuts.
. . . . 7-41
N»m
(5-30
in.
lbs.)

31
mm (23 ft. lbs.)
17
N»m
(150
in.
lbs.)

31
N»m (23 ft. lbs.) 54
N«m
(40 ft. lbs.) 176
N®m
(130 ft. lbs.)
24
N«m
(18 ft. lbs.)
10 N*m (90 in. lbs.)
54
N«m
(40 ft. lbs.)

11
N»m (100
in.
lbs.)
54
N«m
(40 ft. lbs.) J9221-250

G360
SET-TO
TORQUE
SPECIFICATIONS
NP241
TORQUE SPECIFICATIONS

Clutch Housing Bolts
47 N-m (35 ft. lbs.)
Drain/Fill Plugs
47 Nm (35 ft. lbs.)

Front/Rear Bearing
Retainer Bolts
.
22-30
N-m
(16-22
ft. lbs.)

Rear Crossmember Bolts/Nuts
. 68 N-m (50 ft. lbs.)

Shift Cover Bolts 22-30
N-m
(16-22
ft. lbs.)

Skid Plate
And
Crossmember Bolts/Nuts
41 N-m (30 ft. lbs.)

Transfer Case Attaching Nuts
47 Nm (35 ft. lbs.)

Transmission-To-Clutch Housing Bolts
68 N-m (35 ft. lbs.)

U-Joint Clamp Bolts
19 Nm (14 ft. lbs.)

Yoke
Nut 380 N-m (280 ft. lbs.)

J9321-333
DESCRIPTION
TORQUE

Oil Pump
Screws
1.4-1.8
N«m (12-15 in. lbs.)

Yoke
Nut (front/rear) 176-271 N»m (130-200 ft. lbs.)
Vacuum Switch
20-34 N«m (15-25 ft. lbs.)
Range
Lever
Nut
27-34 N»m (20-25 ft. lbs.)

Front
Case-To-Rear
Case
Bolts
.. 27-34 N»m (20-25 ft. lbs.)
Rear
Retainer
Bolts
47-61 N»m (35-45 ft. lbs.)

Extension
Housing
Bolts
35-46 N»m (26-34 ft. lbs.)

Drain/Fill
Plugs
41-54 N*m (30-40 ft. lbs.)

Detent
Plug
16-24
N@m
(12-18 ft. lbs.)
Front
Bearing
Retainer
Bolts
16-24 N»m (12-18 ft. lbs.)

Vacuum Switch
20-34 N*m (15-25 ft. lbs.)
Rear
Case
Stud
Nut 27-34 N*m (20-25 ft. lbs.)

Strut
Mounting Bracket Stud
Nut 27-34 N»m (20-25 ft. lbs.)
J9221-248

NV4500
TORQUE
SPECIFICATIONS
NP205
TORQUE
SPECIFICATIONS

•

WHEELS
AND
TIRES
22 - 1
CONTENTS
page page
TIRES
1
VEHICLE VIBRATION
11

TORQUE SPECIFICATIONS
13
WHEELS
6

TIRES INDEX
page
Cleaning
of
Tires
2

General
Information
1
Pressure
Gauges
. 2

Repairing Leaks
3

Replacement Tires
2

GENERAL
INFORMATION
Tires are designed for each specific vehicle. They
provide the best overall performance for normal op­ eration. The ride and handling characteristics match
the vehicle's requirements. With proper care they
will give excellent reliability, traction, skid resis­
tance, and tread life. These tires have specific load carrying capacities. When correctly inflated, they
will operate properly.
Tires used in cool climates, and with light loads
will have a longer life than tires used in hot climates
with heavy loads. Abrasive road surfaces will accel­ erate tire wear.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain much
greater mileage than careless drivers.
Driving habits that shorten the life of any tire;
• Rapid acceleration and deceleration
• Severe application of brakes • High-speed driving
• Taking turns at excessive speeds
• Striking curbs and other obstacles It is very important to follow the tire rotation in­
terval
IDENTIFICATION Tire type, size, aspect ratio and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 1). Performance tires will have a speed rating letter
after the aspect ratio number. The speed rating is
page

Rotation
. 3

Tire
Inflation
Pressures
2
Tire
Noise
or
Vibration
4

Tire
Wear
Patterns
4

Tread Wear
Indicators
3
not always printed on the tire side wall. The letter S
indicates that the tire is speed rated up to 112 mph.
• Q up to 100 mph
• T up to 118 mph
• U up to 124 mph
• H up to 130 mph
• V up to 149 mph
• Z more than 149 mph (consult the tire manufac­
turer for the specific speed rating)
An All Season type tire will have either M + S, M
& S or M—S (indicating mud and snow traction) im­
printed on the side wall.
RADIAL-PLY TIRES Radial-ply tires improve handling, tread life, ride
quality and decrease rolling resistance. Radial-ply tires must always be used in sets of
four. Under no circumstances should they be used on
the front only. They may be mixed with temporary spare tires when necessary, but reduced speeds are
recommended.
Radial-ply tires have the same load-carrying capac­
ity as other types of tires of the same size. They use
the same recommended inflation pressures.
SPARE TIRE (TEMPORARY) The compact spare tire is designed for emergency
use only. The original tire should be repaired and re­
installed at the first opportunity. Refer to Owner's
Manual for complete details.

WHEELS
AND
TIRES