DODGE TRUCK 1993 Service Repair Manual

21
• 140
IN-VEHICLE
SERVICE-32RH/36RH/37RH/42RH/46RH

•
VALVE BODY CONTROL
PRESSURE
ADJUSTMENTS

There
are two
control pressure adjustments
on the

valve body which
are:
Line pressure
and
throttle pres­
sure.
The valve body must
be
removed from
the

transmission
in
order
to
perform
the
adjust­
ments. Refer
to the
valve body removal/installa­
tion procedures
in
this section. Because line
and
throttle pressures
are
interdepen­
dent (each affects shift quality
and
timing), both
ad­

justments must
be
performed properly
and in the
correct sequence. Adjust line pressure first
and
throt­
tle pressure last.

LINE
PRESSURE
ADJUSTMENT
Measure distance from
the
valve body
to the
inner
edge
of the
adjusting screw with
an
accurate steel scale
(Fig. 27).

Distance should
be 1-5/16 in. (33.4 mm).

If adjustment
is
required, turn
the
adjusting screw
in,
or out, to
obtain required distance setting.
The
1-5/16 in. (33.4 mm)
setting
is an
approximate
setting only. Because
of
manufacturing tolerances,
it

may
be
necessary
to
vary from this dimension
to ob­

tain desired pressure.
One complete turn
of the
adjusting screw changes line
pressure approximately
1-2/3 psi (9 kPa).
Turning
the
adjusting screw counterclockwise increases pressure
while turning
the
screw clockwise decreases pressure.

RH258

Fig.
27
Line
Pressure
Adjustment

THROTTLE
PRESSURE
ADJUSTMENT
Insert Gauge Tool C-3763 between
the
throttle
le­

ver
cam and
kickdown valve
(Fig. 28).

Push
the
gauge tool inward
to
compress
the
kick-
down valve against
the
spring
and
bottom
the
throt­
tle valve. Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until
the
screw head touches throttle lever tang
and the
throttle lever
cam
touches gauge tool. The kickdown valve spring must
be
fully com­
pressed
and the
kickdown valve completely bot­
tomed
to
obtain correct adjustment.

HEX

WRENCH

^
KICKDOWN
yL£_
THROTTLE
LEVER
SPECIAL

" TOOL C-3763
J9121-542

Fig.
28
Throttle
Pressure
Adjustment

TRANSMISSION
COOLER
SERVICE

FLUSHING
COOLERS
AND
LINES
If
a
transmission malfunction contaminates
the

fluid, the cooler
and
lines must
be
reverse flushed
thoroughly. This
is
necessary
to
prevent sludge
and

particles from flowing back into
the
transmission
af­
ter repair.
The
flushing procedure applies
to
stan­dard
and
auxiliary coolers.
Pressure equipment
is
preferred
for
cooler reverse
flushing. However, reverse flushing
can be
performed with hand operated equipment
as
follows.

Flushing
Procedure (1) Identify
and
disconnect cooler pressure
and re­

turn lines
at
transmission
(Fig. 29).

INLET
FITTING
(RETURN
_ LINE)
COOLER
^

PRESSURE
LINE
AND
HOSE OUTLET
FITTING
(PRESSURE LINE)
COOLER RETURN LINE
AND
HOSE
J9121-364

Fig.
29
Transmission
Cooler
Line
Identification

•

IN-VEHICLE
SERVICE-32RH/36RH/37RH/42RH/46RH
21 - 141 (2) Position drain pan under cooler pressure line to
catch material flushed through cooler and lines. (3) Reverse flush cooler using hand operated suc­
tion gun filled with mineral spirits. Insert gun nozzle (or hose) into cooler return line. Then force mineral
spirits into line and through cooler. (4) Continue reverse flushing until fluid exiting
cooler pressure line is clear and free from debris. Re­
place cooler if fluid cannot be pumped through. (5) Clear flushing materials from cooler and lines
with short pulses of compressed air. Insert air gun nozzle into cooler return line and continue short air pulses until all fluid is cleared from cooler and lines. (6) Pump one quart of fresh automatic transmission
fluid through cooler and lines before reconnecting lines.
CHECKING COOLER FLUID FLOW Cooler flow is checked, by measuring the amount of
fluid pumped through the cooler in a specified time
by the transmission oil pump. (1) Disconnect cooler return line from transmission
and place it in one quart test container.
(2) Add extra quart of fluid to transmission.
(3) Use stopwatch to check test time.
(4) Shift into Neutral.
(5) Start and run engine at curb idle speed and
note cooler flow. A minimum of one quart (0.9 liter)
of fluid should flow into test container in 20 seconds. (6) If fluid flow is intermittent, flows less than one
quart in 20 seconds, or fails to flow at all, cooler is
plugged or damaged and should be replaced.
MAIN COOLER REPLACEMENT The main transmission cooler is located in the ra­
diator lower tank. The cooler is not a serviceable component. If the cooler is damaged in any way, the
radiator will have to be replaced.
AUXILIARY COOLER REPLACEMENT (1) Remove grille. Also remove A/C condenser for
access if necessary.
(2) Remove brackets securing cooler to radiator
and radiator support (Fig. 30).
(3) Tag cooler hoses for installation reference.
(4) Position drain pan under cooler lines.
(5) Loosen cooler connecting hose clamps and dis­
connect hoses.
(6) Remove cooler
(7) Connect cooler to hoses.
(8) Position cooler on radiator and install cooler
support brackets and attaching fasteners. (9) Tighten cooler hose clamps securely.
(10) Install grille and air conditioning condenser, if
removed.
(11) Check and adjust transmission fluid level.

ALUMINUM
THREAD
REPAIR
Damaged or worn threads in the aluminum trans­
mission case and in the valve body can be repaired
with Heli-Coil thread inserts, or equivalent. Stain­ less steel inserts are preferred. Essentially, thread repair consists of drilling out
the worn or damaged threads, tapping the hole with a special tap and installing a Heli-Coil, or equivalent
thread insert into the tapped hole. This procedure re­
turns the hole threads to original size. Heli-Coil, or equivalent, tools and inserts are readily available
from most automotive parts suppliers. CONNECTING HOSE RADIATOR SUPPORT
FAN
SHROUD
PRESSURE LINE
AUXILARY COOLER
CONNECTING HOSE PRESSURE
LINE
HFRONT

Fig.
30 Auxiliary
Cooler
Mounting
RETURN
LINE J9021-74

!1
- 142
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION

• AUTOMATIC TRANSMISSION REMOWAL AND INSTALLATION

INDEX
page
Dverdrlve
Unit
Installation
150

Overdrive
Unit
Removal-42RH/46RH
........ 149

Pump
Oil
Seal
146

Starter
Ring Gear Replacement
144

Torque Converter
and
Drive
Plate
Service
..... 144

Transmission
and
Torque Converter
Installation—
2-Wheel Drive
146
page
Transmission
and
Torque Converter
Installation—
4-Wheel Drive
. . .' 148

Transmission
and
Torque Converter Removal— 2-Wheel Drive
142

Transmission
and
Torque Converter Removal
—
4-Wheel Drive
143

TRANSMISSION
AND
TORQUE CONVERTER REMOVAL—2-WHEEL DRIVE The
transmission and torque converter should
be removed as an assembly to avoid component damage. The converter drive plate, pump bush­
ing, or oil seal can be damaged if the converter
is left attached to the driveplate during removal. Be sure to remove the transmission and con­
verter as an assembly.
(1) Raise vehicle.
(2) Disconnect or remove exhaust components as
needed for service access.
(3) Remove engine-to-transmission struts, if
equipped. (4) Disconnect fluid cooler lines at transmission.
(5) Remove starter motor and cooler line bracket.
(6) Remove torque converter bolt access cover.
(7) Remove transmission oil pan, drain fluid and
reinstall pan. (8) Remove transmission fill tube bracket bolts and
remove tube and O-ring from transmission case. (9) Mark torque converter and drive plate for as­
sembly alignment (Fig. 1). Note that bolt holes in
crankshaft flange, drive plate and torque converter
all have one offset hole. (10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on
damper pulley bolt. (11) Mark propeller shaft and axle yokes for as­
sembly alignment. Then disconnect and remove pro­
peller shaft (Fig. 2). (12) Disconnect wires from park/neutral position
switch and transmission solenoids. (13) Disconnect gearshift rod and torque shaft as­
sembly from brackets on transmission and frame

rail.
(14) Disconnect throttle valve rod (or cable) from
transmission throttle lever. (15) Disconnect vehicle speed sensor wires.
(16) Support engine with Fixture C-3487-A and
adapters, or a similar tool. (17) Support transmission with transmission jack.
Fig.
1 Marking Converter And
Driveplate
For

Alignment
Reference Secure transmission to jack with safety chains.
(18) Raise transmission slightly with jack to re­
lieve load on crossmember and insulator. (19) Remove bolts attaching transmission to insu­
lator and crossmember and remove crossmember and
brackets. (20) Remove bolts attaching converter housing to
engine block.
(21) Carefully work transmission and converter as­
sembly rearward until clear of engine block dowels and crankshaft. (22) Secure converter in housing with small
C-clamp attached to edge of housing. (23) Lower transmission and remove assembly
from under vehicle.
(24) Remove C-clamp and carefully slide converter
out of pump. Store converter on bench during service
operations. Cover converter hub with tape, card­
board, or paper to prevent dirt entry.

•

AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION
21 - 143

AXLE

YOKE PROPELLER

SHAFT
YOKE

U-JOINT
RETAINER RETAINER
BOLT

(170
IN-LBS)
TRANSMISSION
OUTPUT

SHAFT
J9021-146

Fig.
2 Propeller Shaft Attachment
TRANSMISSION
AND TORQUE CONVERTER

REMOVAL—4-WHEEL
DRIVE
The transmission and torque converter should
be removed as an assembly to avoid component damage. The converter drive plate, pump bush­
ing, or oil seal can be damaged if the converter
is left attached to the driveplate during removal.
Be sure to remove the transmission and con­
verter as an assembly. (1) Raise vehicle.
(2) Disconnect or remove exhaust components as
needed for service access. (3) Remove engine-to-transmission struts, if
equipped. (4) Disconnect fluid cooler lines at transmission. (5) Remove starter motor and cooler line bracket.
(6) Remove torque converter access cover.
(7) Remove transmission oil pan, drain fluid and
reinstall pan. (8) Remove transmission fill tube bracket bolts and
remove tube and O-ring from transmission case. (9) Mark torque converter and drive plate for as­
sembly alignment. Note that bolt holes in crankshaft
flange, drive plate and torque converter all have one
offset hole. (10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft using breaker bar and
socket installed on damper pulley bolt. (11) Mark front/rear propeller shaft and axle yokes
for assembly alignment. (12) Disconnect and remove both propeller shafts
(Fig. 2). (13) Disconnect wires from park/neutral position switch and transmission solenoids.

(14)
Disconnect transmission gearshift rods and
torque shaft assembly from brackets on transmission and frame rail.
(15) Disconnect throttle valve cable from transmis­
sion throttle lever.
(16) Remove transfer case skid plate and skid plate
crossmember (Fig. 3). (17) Disconnect wires from vehicle speed sensor.
(18) Disconnect necessary vacuum harness hoses.
SKID

PLATE

CROSSMEMBER

TRANSFER
CASE
SKID

PLATE
J9121-525

Fig.
3
Skid
Plate
Mounting
(19) Disconnect transfer case shift lever from
range lever.
(20) Support transfer case with transmission jack.
Secure transfer case to jack with safety chains.
(21) Remove nuts attaching transfer case to trans­
mission adapter.
(22) Pull transfer case rearward until clear of
transmission. Lower jack and move transfer case
from under vehicle. Then remove transfer case from
jack and leave on bench until ready for installation.
(23) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(24) Remove bolts/nuts attaching transmission in­
sulator plate to rear crossmember (Figs. 4 and 5).
(25) Remove bolts/nuts attaching crossmember and
brackets to frame rails and remove crossmember.
(26) Support engine with Fixture C-3487-A and
adapters, or a jack stand and wood blocks.
(27) Remove bolts attaching converter housing to
engine. (28) Carefully work transmission-converter assem­
bly rearward until clear of crankshaft and engine
block dowels.

21-144
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION

TRANSMISSION
ADAPTER
BOLT AND

;
WASHER
(2)

INSULATOR
SPACER
(2)

UPPER

INSULATOR
(2)

INSULATOR
MOUNTING PLATE

WITH
7"
RAIL
(135
"
WHEELBASE) LOWER
INSULATOR
(2)

J9121-532

Fig.
4
Transmission-To-Crossmember
Attachment (Except 46RH)
(29)
Secure converter in place with small C-clamp
attached to edge of converter housing.

(30)
Lower transmission and remove assembly
from under vehicle.

(31)
Remove C-clamp securing converter in hous­
ing.

(32)
Carefully slide converter out of pump and re­
move it from transmission. Place converter on bench and cover converter hub with tape, cardboard, or pa­
per to prevent dirt entry.

TORQUE CONVERTER
AND
DRIVE PLATE SERVICE
After the transmission has been removed, the drive
plate and torque converter can be replaced or re­
moved for service access.
The torque converter is not a serviceable part. If
the converter is contaminated by a transmission mal­
function, or damaged in any way, it must be replaced as an assembly. Do not attempt to flush a con­
verter contaminated by metal or clutch facing
particles. Flushing will not remove these con­
taminants.
A new torque converter and oil pump are used
in 1993, 42RH transmissions. The new converter
has a different style drive hub. The hub was changed to accept the new design drive flats on
the oil pump inner gear. The drive flats replace
the square lugs used previously. If converter re­ placement should become necessary, be sure to
use the new style converter. The new converter and oil pump are not interchangeable with pre­
vious style parts.

STARTER
RING GEAR
REPLACEMENT

CAUTION:
The
starter
ring
gear
on
standard
torque

converters
can be
replaced when necessary. How­
ever,
the
ring gear
on
torque converters with
a
modulated converter clutch, cannot
be
replaced.
The heat from
welding
will
damage
the
converter
clutch friction material. Converters with
a
clutch
must
be
replaced
as an
assembly
if the
ring gear
is

damaged.

RING GEAR REMOWAL
(1) Cut through weld material at rear side of ring
gear with a hack saw or grinding wheel. Be careful
to avoid cutting or grinding into front cover. (2) Scribe heavy line on front cover next to front
face of ring gear. Line is needed to properly locate new gear on converter. (3) Support torque converter on front cover with
blocks of wood (Fig. 6) Position blocks adjacent to converter lugs to avoid altering lug position. The
torque converter must not rest on the front cover hub during this operation.

•
AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION
21 -
145
ITEM SET-TO-TORQUE
SPECIFICATION

(§)
203
N»m
(150
ft. lbs.)
(D
41
N*m
(30
ft. lbs.)
©
m
N«m
(50
ft. lbs.)

WITH

7"
RAIL
TRANSFER
CASE
Fig.
5
Transmission~To-Cross
(4) Remove ring gear with drift
and
hammer.
Tap

downward
on
gear near welded areas
to
break
any

remaining weld material
(Fig. 6).

(5)
Tap
around ring gear until
it
comes
off
con­
verter.
(6) Smooth weld areas
on
converter with
a
mill
file.
Fig.
6
Removing
Starter
Ring
Gear
mber
Attachment
(With
46RH)
RING GEAR INSTALLATION (1) Heat
and
expand
new
ring gear
for
installation
on converter.
Any of the
following methods
are ac­
ceptable:
(a) OVEN: Place gear
in
oven
and set
tempera­
ture
at
200-250°
F (93° C)
Allow ring gear
to re­

main
in
oven
for 15 to 20
minutes.

(b)
BOILING WATER: Place ring gear
in
shal­
low container.
Add
water
and
heat
for
approxi­
mately eight minutes after water
has
come
to a

boil. (c) STEAM: Place ring gear
on a
flat surface
and

direct steam flow around gear
for
approximately
2
minutes.
(2) After ring gear
is
expanded
by
heating, imme­
diately place gear
in
position
on
converter front cover. (3) Quickly
tap
gear onto cover evenly with plastic
or rawhide mallet. Continue tapping gear until face
of gear
is
even with scribe line (made during
re­

moval)
on the
front cover.
(4) Before proceeding, make sure gear
is
even with
scribed line around full circumference
of the
front cover.
(5)
The
following recommendations
are
provided
as

an
aid to
successfully welding
a new
ring gear
to the
converter.
•
Do NOT
weld with oxy-acetylene equipment

21 - 146
AUTOMATIC
TRANSMISSION REMOVAL
AND
INSTALLATION

• • Use a D.C. welder set at straight polarity, or use
an A.C. welder if the proper electrode is available
• Use 1/8 inch diameter welding rod and a welding
current of 80 to 125 amps. • Direct arc at intersection of gear and front cover at
an angle of 45° from rear face of gear.

(6)
Weld new ring gear to torque converter front
cover. Take care to place same amount of weld mate­
rial (or as nearly as possible) in original weld loca­

tions.
This is essential in maintaining converter
balance. Position welds alternately on opposite sides of converter and ring gear to minimize distortion.
(7) Inspect gear teeth and remove any nicks, raised
metal, weld spatter, or rough surfaces.

PUMP
OIL
SEAL

Seal
Removal
On 32RH/42RH pumps, remove the seal with Spe­
cial Tool C-3981B (Fig. 7).
On 36RH/37RH/46RH pumps, remove the seal with
Special Tool C-3861 (Fig. 8). To use the remover tool, First start the tool into
the seal by hand. Next, thread the tool into the seal as far as it will go. Use a wrench on the tool hex to
turn the tool. Continue tightening until all the tool
threads firmly grip the metal part of the seal. Then
tighten the tool puller screw to withdraw the seal
from the pump body.
Fig. 7 Pump Seal Removal—42RH Fig. 8 Pump Seal Removal—46RH
Seal
Installation

On 32RH/42RH pumps, use Installer Tool C-4193
to install the new seal (Fig. 9).
On 36RH/37RH/46RH pumps, use Installer Tool
C-3860-A (Fig. 9).
To use the tool, place the seal in the pump opening
with the seal lip facing inward. Then tap the seal into place with the installer tool (Fig. 9). Tool Han­
dle C-4171 may be used with the installer tool if de­ sired.
J932M80
Fig. 9 Pump Seal Installation

TRANSMISSION
AND TORQUE CONVERTER INSTALLATION—2-WHEEL DRIVE

(1) Mount transmission on jack. Secure transmis­
sion with safety chains. (2) Check converter hub and hub drive notches for
sharp edges, burrs, scratches, or nicks. Polish hub
and notches with 400 grit wet/dry paper or crocus
cloth if necessary. Hub surface must be smooth to avoid damaging pump seal at installation. (3) Lubricate converter drive hub and pump seal
lip with transmission fluid. (4) Install converter in oil pump.
(5) Verify that converter is fully seated. Use
straight edge and steel ruler to check seating (Fig.
10).
Surface of converter lugs should be approxi­
mately 13 mm (1/2 in.) to rear of straight edge when
converter is fully seated. (6) Temporarily secure converter with C-clamp at­
tached to housing or with metal strap attached across converter housing. (7) Mount transmission on jack and secure it with
safety chains. (8) Check condition of converter driveplate. Re­
place plate if cracked, distorted or damaged. If driveplate replacement was necessary, be sure
transmission dowel pins are seated in engine
block and protrude far enough to held transmis­ sion in alignment. (9) Raise transmission and align converter with
crankshaft and drive plate.

•

AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION
21 - 147

Fig.
10 Checking Torque Converter Seating (10) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
dowels in engine block.
(11) Rotate converter until alignment mark scribed
on converter is aligned with mark on driveplate.
Off­
set holes in plate are next to 1/8 in. hole in inner cir­
cle of plate (Fig. 1).
(12) Carefully work transmission forward until
converter hub is seated.
(13) Install bolts attaching converter housing to
engine block. (14) Install crossmember and brackets.
(15) Lower transmission onto crossmember and in­
sulator. Then install bolts attaching transmission
mount to crossmember.
(16) Remove fixture used to support engine.
(17) Connect wires to vehicle speed sensor.
(18) Install new plastic retainer grommet on any
shift linkage rod or lever that was disconnected. Old
grommets should not be reused. Use pry tool to re­
move rod from grommet and cut away old grommet.
Use pliers to snap new grommet into lever and to
snap rod into grommet.
(19) Connect gearshift linkage and transmission
throttle cable to levers on manual valve shaft.
(20) Connect wires to park/neutral position switch,
transmission solenoid(s) and oxygen sensor. Be sure
transmission harnesses are properly routed (Figs. 11 and 12).

CAUTION:
It is
essential
that
correct length bolts
be
used
to
attach
the
converter
to the
driveplate. Bolts

that
are too
long
will
damage
the
clutch surface
in the
converter.
If new
bolts
are
required,
use the
bolts
specified
in
this procedure
and in the
parts
book only.
SENSOR

NEUTRAL
START
AND

BACKUP
LAMP
SWITCH

J9021-76

Fig.
11
Transmission
Wire
Routing—32RH/36RH
ENGINE

J9021-75
Fig.
12
Transmission
Wire
Routing—42RH/46RH

(21) Verify converter bolt length. Bolt measure­
ment is from bottom (underside) of bolt head to end of bolt threads.
• On 9.5 in., 3-lug converter, bolts should be 0.46 in. (11.7 mm) long.

21 - 148
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION

•

ITEM
TORQUE

A
27-54
N-m
(20-40
ft. lbs.)

B
9-14
N-m
(80-120
in.
lbs.)

C
3-6 N-m
(30-50
in. lbs.)

D
47-88
N-m
(35-65
ft. lbs.)

E
14-20 N-m
(125-175
in. lbs.)
PLATE

FILL

TUBE

BRACKET
TRANSMISSION

DIPSTICK

DAMPER

WEIGHT

STRUT
DUST

COVER
J9321-232

Fig. 13 Transmission And Fill Tube Attachment
3-lug converter, tighten
4-lug converter, tighten • On 9.5 in., 4-lug converter, bolts should be 0.52 in.
(13.2 mm) long.
• On 10.75 in., 4-lug converter, bolts should be 0.44
in. (11.2 mm) long. (22) Install torque converter attaching bolts.
Tighten bolts as follows:
• On models with 9.5 in.,
bolts to 54 Nnn (40 ft. lbs.) • On models with 9.5 in.,
bolts to 74 Nnn (55 ft. lbs.) • On models with 10.75 in., 4-lug converter, tighten
bolts to 31 Nnn (270 in. lbs.)
• On diesel models, tighten converter bolts to 47
Nnn (35 ft. lbs.) torque (23) Install converter housing dust cover. (24) Install starter motor and cooler line bracket.
(25) Connect cooler lines to transmission.
(26) Install transmission fill tube (Fig. 13). Install
new O-ring seal on tube before installation. (27) Install any exhaust components that were re­
moved, or moved for service access. (28) Align and install propeller shaft. Tighten
shaft U-joint clamp bolts to 19 Nnn (170 in. lbs.)
torque. (29) Lower vehicle.
(30) Fill transmission with Mopar ATF Plus, Type

7176,
or Mopar Dexron II if ATF Plus is not readily
available. (31) Check and adjust gearshift and throttle valve
linkage if necessary.

TRANSMISSION
AND
TORQUE CONVERTER INSTALLATION—4-WHEEL DRIVE

CAUTION:
The
transmission cooler
and
lines must be flushed
if
repair
corrected
a
problem that gener­
ated
sludge,
metal particles,
or
clutch friction mate­ rial.
The
torque
converter
should
also
be replaced

when contaminated
by a
malfunction.
The
transmis­
sion,
fluid
and
converter
will
be
contaminated again if residue/debris
is not
flushed from
the
cooler
and

lines
beforehand.

(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish hub and notches with 400 grit paper or crocus
cloth if necessary. Hub must be smooth to avoid dam­ aging pump seal during installation.
(2) Lubricate converter hub and pump seal lip with
transmission fluid.
(3) Position converter hub so drive slots will be
aligned with pump gears. Then carefully insert con­
verter hub into pump and gears.
(4) Verify that converter is fully seated. Use
straight edge and steel ruler to check seating (Fig.

•

AUTOMATIC
TRANSMISSION
REMOVAL
AND
INSTALLATION
21 - 149
10).
Surface of converter lugs should be approxi­
mately 13 mm (1/2 in.) to rear of straight edge when converter is fully seated.
(5) Temporarily secure converter in pump and
housing with C-clamp attached to housing edge, or
with metal strap attached across converter housing.
(6) Position transmission on jack. Secure transmis­
sion to jack with safety chains.
(7) Check condition of converter driveplate. Re­
place plate if cracked, distorted or damaged. If driveplate replacement was necessary, be sure
transmission dowel pins are seated in engine block and protrude far enough to held transmis­ sion in alignment.
(8) Coat pilot hub of torque converter with trans­
mission fluid.
(9) Raise transmission and align converter with
drive plate and crankshaft.
(10) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
dowels on engine block.
(11) Rotate converter to align marks scribed on
converter and driveplate. Offset holes in plate are
next to 1/8 in. hole in inner circle of plate (Fig. 1).
(12) Carefully work transmission forward and over
engine block dowels until converter hub is seated in crankshaft.
(13) Install bolts attaching converter housing to
engine.
(14) Install crossmember.
(15) Lower transmission onto crossmember and in­
stall bolts attaching transmission and insulator to
crossmember (Figs. 4 and 5). (16) Remove fixture used to support engine.
(17) Connect vehicle speed sensor wires. (18) Install new plastic retainer grommet on any
shift linkage rod or lever that was disconnected. Old
grommets should not be reused. Use pry tool to re­
move rod from grommet and cut away old grommet.
Use pliers to snap new grommet into lever and to snap rod into grommet. (19) Connect gearshift and throttle linkage to
transmission. (20) Connect wires to park/neutral position switch,
transmission solenoids and to oxygen sensor. Be sure
transmission harnesses are properly routed.

CAUTION:
It is essential
that
correct length
bolts
be

used
to
attach
the
converter
to the
driveplate.
Bolts

that
are too long
will
damage
the
clutch
surface
in
the converter. If new
bolts
are required, use the
bolts
specified in this procedure and in the parts
book
only.

(21) Verify converter bolt length. Bolt measure­
ment is from bottom (underside) of bolt head to end
of bolt threads. • On 9.5 in., 3-lug converter, bolts should be 11.7
mm (0.46 in.) long.
• On 9.5 in., 4-lug converter, bolts should be 13.2
mm (0.52 in.) long.
• On 10.0 in., 4-lug converter, bolts should be 13.2
mm (0.52 in.) long.
• On 10.75 in., 4-lug converter, bolts should be 11.2
mm (0.44 in.) long.
(22) Install torque converter bolts. Tighten bolts as
follows:
• On models with 9.5 in., 3-lug converter, tighten
bolts to 54 Nnn (40 ft. lbs.).
• On models with 9.5 in., 4-lug converter, tighten
bolts to 74 Nnn (55 ft. lbs.).
• On models with 10.0 in., 4-lug converter, tighten
bolts to 74 Nnn (55 ft. lbs.) torque.
• On models with 10.75 in., 4-lug converter, tighten
bolts to 31 Nnn (270 in. lbs.).
• On diesel models with 12.2 in. converter, tighten
bolts to 47 Nnn (35 ft. lbs.) torque.
(23) Install converter housing access cover. (24) Install starter motor and cooler line bracket.
(25) Connect cooler lines to transmission.
(26) Install transmission fill tube. Install new
O-ring seal on tube before installation.
(27) Install any exhaust components removed for
service access. (28) Support transfer case on transmission jack.
Secure transfer case to jack with safety chains. (29) Install gasket on transmission adapter. Coat
gasket with Mopar perfect, seal, or silicone sealer be­
forehand. (30) Install transfer case on transmission. Tighten
transfer case attaching nuts to 47 Nnn (35 ft. lbs.) torque. (31) Remove jack supporting transfer case.
(32) Connect transfer case shift lever to range le­
ver. (33) Align and install propeller shafts. Tighten
clamp bolts to 19 Nnn 170 in. lbs.) torque. (34) Install transfer case skid plate and crossmem­
ber. (35) Lower vehicle.
(36) Fill transmission with Mopar ATF Plus, Type
7176, or Mopar Dexron II if ATF Plus is not readily
available. (37) Check and adjust gearshift, throttle valve and
transfer case shift linkages if necessary.

OVERDRIVE
UNIT
REMOVAL—42RH/46RH
The following removal and installation procedures
apply to the 42RH/46RH overdrive unit only. If the
complete transmission assembly must be removed,
refer to the Transmission And Converter Removal and Installation procedures. (1) Shift transmission into Park.
(2) Raise vehicle.