DODGE TRUCK 1993 Service Repair Manual

21 - 150
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION

• (3) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan. (4) If overdrive unit had malfunctioned, or if fluid
is contaminated, remove entire transmission. If diag­
nosis indicated overdrive clutch or governor problems
only, remove overdrive unit only.
(5) Mark propeller shaft universal joint and axle
pinion yoke for alignment reference at installation (Fig. 14). On 4WD models, mark both shafts for
ref­

erence.

Fig.
14 Marking Propeller Shaft And Axle Yoke For
Alignment
Reference
(6) Disconnect and remove propeller shaft. On
4WD models, remove both shafts.
(7) On 4WD models, disconnect transfer case shift
linkage and distance sensor and remove transfer

case.

(8) Support transmission with transmission jack.
(9) Remove rear crossmember.
(10) Remove vehicle speed sensor and speedometer
adapter.
(11) Remove bolts attaching overdrive unit to
transmission (Fig. 15).

CAUTION:
Support
the
overdrive unit with
a
jack before moving
it
rearward. This
is
necessary
to
pre­
vent damaging
the
intermediate shaft.
Do not
allow
the shaft
to
support
the
entire
weight
of the
over­ drive unit.

(12) Work overdrive unit rearward and off trans­
mission intermediate shaft.
(a) If overdrive unit does not require service, in­
sert Tool 6227-2 in overdrive unit overrunning
clutch and planetary gear to maintain spline align­
ment. If clutch and gear splines rotate out of
alignment, overdrive unit will have to be disas­
sembled in order to realign splines.
(b) If overdrive unit does requires service, refer
to Overdrive unit Overhaul section.
Fig.
15 Removing/Installing Overdrive Attaching

Bolts
(13) Remove and retain overdrive piston thrust
bearing. Bearing may remain on piston or in clutch hub during removal.
(14) Position drain pan on workbench.
(15) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case. (16) Examine fluid for clutch material or metal
fragments. If fluid contains these items, overhaul
will be necessary.

OVERDRIVE
UNIT INSTALLATION
(1) Be sure Alignment Tool 6227-2 is fully seated
in overdrive planetary and overrunning clutch
splines before moving unit.
(2) If overdrive piston retainer was not removed
during service and original case gasket is in good
condition, proceed to step (6). However, if original case gasket is not reusable, trim and install replace­
ment gasket as described in steps (3) through (5).
(3) Cut out old case gasket around piston retainer
with razor knife (Fig. 16). (4) Use old gasket as template and trim new gas­
ket to fit. (5) Position new gasket over piston retainer and on
transmission case. Use petroleum jelly to hold gasket in place if necessary. Do not use any type of sealer
to secure gasket. Use petroleum jelly only. (6) Install selective spacer on intermediate shaft if
removed. Spacer goes in groove just rearward of shaft
rear splines (Fig. 17). (7) Install overdrive piston in retainer if removed.
Lubricate piston seals with Ru-Glyde, Door-Eze or
petroleum jelly to ease installation. Be sure piston lo­
cating lugs are aligned in piston retainer. (8) Install thrust bearing in overdrive unit sliding

hub.
Use petroleum jelly to hold bearing in position.

CAUTION:
Be
sure
the
shoulder
on the
inside diam­

eter
of the
bearing
is
facing forward.

•

AUTOMATIC
TRANSMISSION
REMOVAL
AND
INSTALLATION
21 - 151

Fig.
17
Intermediate
Shaft Selective
Spacer
Location (9) Raise overdrive unit on transmission jack and
align it with intermediate shaft. (10) Carefully remove Alignment Tool 6227-2 from
overdrive compounder.
(11) Slide overdrive unit straight onto intermedi­
ate shaft. Be sure park rod goes into park lock reac­
tion plug at same time.

CAUTION:
Do not tilt or
jounce
the
overdrive unit
during installation. This could cause
the
overdrive planetary
and
overrunning clutch splines
to
rotate

out
of
alignment.
If the
splines
rotate
out of
align­ ment,
it
will
be
necessary
to
disassemble
the
over­
drive unit
to
realign
the
splines
with
Tool
6227-2.

(12) Align slip-fit governor tubes in piston retainer
and work compounder unit forward on intermediate
shaft and seat unit against transmission case.
(13) Install bolts attaching overdrive unit to trans­
mission. Tighten bolts in diagonal pattern to 34 N»m (25 ft-lbs).
(14) Install crossmember.
(15) On 4WD models, install transfer case and con­
nect shift linkage and distance sensor. (16) Install speedometer adapter and vehicle speed
sensor. Be sure to index adapter.
(17) Connect vehicle speed sensor and overdrive so­
lenoid wires.
(18) Align and install propeller shaft, or shafts on
4WD models. (19) If valve body was also removed, adjust bands,
install valve body and install transmission oil pan and gasket.
(20) Lower vehicle and refill transmission with
Mopar ATF Plus, Type 7176. Use Mopar Dexron II if
ATF Plus is not readily available.

21
- 152
TRANSMISSION OVERHAUL—32RH

•
TRANSMISSION
OWERHAUL—32RH

INDEX

page
Extension Housing
and
Park Lock Component Overhaul
............................ 160

Front
Clutch Overhaul
165

Front
Servo
and
Band Overhaul
175

Governor
and
Park Gear Overhaul
160

Oil Pump
and
Reaction Shaft Support Overhaul
. 162

Overhaul Service
Information
158

Overrunning CIutch—Low-Reverse Drum—Rear

TRANSMISSION
DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
process. (2) Remove throttle and shift levers from valve
body manual shaft and throttle lever shaft. (3) Mount transmission in repair stand C-3750-B
or similar type stand (Fig. 1).
Fig.
1
Transmission
Mounted
On Repair
Stand

(4)
Remove bolts attaching extension housing to
transmission case. Then remove rear bearing locat­
ing ring access cover from housing (Fig. 2)
(5) Spread rear bearing locating ring with parallel
jaw snap ring pliers (Fig. 2). Then work extension housing off rear bearing and output shaft. Remove
housing gasket after removing housing.

(6)
Remove rear bearing and snap ring from out­
put shaft (Fig. 3).
page
Support Overhaul
158

Planetary Gear
Train-Output
Shaft Overhaul
. . 171

Rear
Clutch Overhaul
168

Rear
Servo
and
Band Overhaul
............. 175

Transmission Assembly
and
Adjustment
...... 184

Transmission
Case
Cleaning
and
Inspection
... 158

Transmission Disassembly
152

Valve Body Service
and
Adjustment
......... 176
Fig.
2 Extension
Housing
Removal—32RH

Fig.
3 Output Shaft Rear Bearing Position—32RH (7) Remove oil pan bolts and remove pan and gas­
ket. (8) Remove park/neutral position switch and seal
(Fig. 4). (9) Remove hex head valve body attaching bolts
(Fig. 5). (10) Disconnect solenoid wire from case connector
(Fig. 6). (11) Lift valve body upward, guide park rod out of
case opening and remove valve body (Fig. 5). (12) Remove accumulator spring and piston (Fig.

8).

•

Fig.
4 Park/Neutral Position
Switch
Removal/
Installation

Fig.
5
Valve
Body
Attaching
Bolt
Locations—32RH

Fig.
6
Solenoid
Wire
Connection—32RH
(13) Remove front band reaction pin access plug
(Fig. 9). Plug is accessible through converter hous­
ing. Use 1/4 inch drive extension to remove plug as
shown. (14) Loosen front band adjusting screw locknut 4-5

turns.
Then tighten band adjusting screw until band is tight around front clutch retainer. This prevents
front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
TRANSMISSION
OVERHAUL—32RH
21-113

Fig.
7 Removing/Installing
Valve
Body—32RH

Fig.
8 Removing/Installing
Accumulator
Piston
And
Spring—32RH

Fig.
9 Removing/Installing Front
Band
Reaction Pin
Access
Plug—32RH
(15) Remove oil pump bolts.
(16) Thread bolts of Slide Hammer Tools C-3752
into threaded holes in pump body flange (Fig. 10).
(17) Bump slide hammer weights outward to re­
move pump and reaction shaft support assembly from
case (Fig. 10).
(18) Loosen front band adjusting screw until band
is completely loose. VALVE

21

- 154
TRANSMISSION OVERHAUL—32RH

•

Fig.
10
Removing
Oil
Pump/Reaction
Shaft
Support
Assembly—32
RH
(19) Squeeze front band together and remove band
strut (Fig. 11).

Fig.
11 Removing/Installing Front
Band
Strut—32RH (20) Remove front band reaction pin with pencil
magnet. Pin is accessible from converter housing side of case (Fig. 12).
Fig.
12
Removing
Front
Band
Reaction
Pin—32RH
(21) Remove front band lever (Fig. 13)

Fig.
13 Removing/Installing Front
Band
Lever—32RH
(22) Slide front band rearward and onto driving
shell. Band will not be removed until after front/rear
clutch removal. (23) Remove front and rear clutch units as assem­
bly. Grasp input shaft, hold clutch units together and remove them from case (Fig. 14).

J9121-124

Fig.
14
Removing
Front/Rear
Clutch
Assemblies—32RH

(24) Lift front clutch off rear clutch (Fig. 15). Set
clutch units aside for overhaul. (25) Remove output shaft thrust washer from out­
put shaft (or from rear clutch hub). (26) Remove output shaft thrust plate from output
shaft hub (Fig. 16).

TRANSMISSION
OVERHAUL—32RH
21 - 115

FRONT

CLUTCH

REAR

CLUTCH
J9121-125
Fig.
15 Separating Front/Rear
Clutch
Assemblies—32
RH

OUTPUT
SHAFT HUB

OUTPUT
SHAFT

THRUST
PLATE
J9121-126 Fig.
16 Removing/Installing Output Shaft Thrust
Plate-32RH
(27) Slide front band off driving shell (Fig. 17) and
remove band from case. (28) Remove governor body snap ring (Fig. 18).
(29) Remove E-clip from one end of governor valve
shaft and remove valve and shaft from governor body
(Fig. 19). Reinstall E-clip on shaft to avoid losing it.
(30) Loosen bolts attaching governor body to park
gear.
(31) Mark position of governor body on park gear
with center punch or scriber.
(32) Remove governor body and park gear as as­
sembly (Fig. 20). Work park gear out of rear support
and slide assembly off output shaft. ^
DRIVING

„
SHELL

J9121-127 Fig.
17 Front
Band
Removal/Installation—32RH

GOVERNOR
BODY

SNAP
RING
PARK

GEAR

Fig.
18 Removing/Installing
Governor
Body Snap Ring-32RH
E-CLIP
(2
REQ'D)

GOVERNOR

VALVE

V
SHAFT

Fig.
19
Removing
Governor
Valve
And Shaft—32RH

21
- 156
TRANSMISSION OVERHAUL—32RH
GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR

Fig. 20 Removing/Installing Governor And Park Gear—32RH (33) Remove planetary geartrain as assembly (Fig.

21).
Support geartrain with both hands during re­
moval. Do not allow machined surfaces on output shaft to become nicked or scratched. Fig. 21 Planetary Geartrain Removal—32RH
(34) Loosen rear band adjusting screw 4-5 turns.
(35) Remove snap ring that secures low-reverse
drum to rear support hub, however do not remove
drum at this time (Fig. 22). (36) Remove rear band upper and lower reaction
pins with parallel jaw snap ring pliers (Fig. 23). Spread plier jaws in pin bore to grip pin. Then twist
and pull pins to remove them as shown.
(37) Remove rear band lever and strut.
(38) Mark position of rear support for assembly
reference (Fig. 24). Use scriber or center punch to
mark case and support.
(39) Remove rear support bolts and remove support
from low-reverse drum and case (Fig. 25). Keep rear Fig. 23 Removing Rear Band Reaction
Pins—32RH

support bolts together for assembly reference.
(40) Remove bolts attaching overrunning clutch
cam to case (Fig. 26).
(41) Remove low-reverse drum and overrunning
clutch as assembly. Slide drum and clutch through
rear band and out of case. Set drum and clutch as­ sembly aside for cleaning and inspection.
(42) Remove rear band from case.
(43) Compress front servo rod guide about 1/8 in.
with valve spring compressor tool C-3422-B (Fig. 27).
A C-clamp and tool C-4470 can also be used to com­
press rod guide.

•

TRANSMISSION
OVERHAUL—32RH
21 - 157

Fig.
24 Marking
32RH
Rear
Support
For
Assembly
Reference

Fig.
26 Overrunning
Clutch
Cam
Bolt
Locations—32RH
(44) Remove front servo rod guide snap ring (Fig.

27).
Excercise caution when removing snap ring. Servo bore can be scratched or nicked if care is
not excercised.
(45) Remove compressor tools and remove front
servo rod guide, spring and servo piston.

Fig.
27
Compressing
Front
Servo
Rod
Guide—32RH
(46) Compress rear servo spring retainer about
1/16 in. with C-clamp and Tool C-4470 or SP-5560
(Fig. 28). Valve Spring Compressor C-3422-A can
also be used to compress spring retainer.
(47) Remove rear servo spring retainer snap ring.
Then remove compressor tools and remove rear servo spring and piston.
Fig.
28
Compressing
Rear
Servo
Spring—32RH

21 - 158
TRANSMISSION
OVERHAUL—32RH

•
OVERHAUL SERVICE
INFORMATION

Inspect all the transmission bushings during over­
haul. Bushing condition is important as worn, scored
bushings contribute to low pressures, clutch slip and accelerated wear of other components. Do not replace
bushings as a matter of course. Replace bushings
only when actually worn or scored. Use recommended tools to replace bushings. The
tools are sized and designed to remove, install and seat bushings correctly, The bushing replacement
tools are included in Bushing Tool Set C-3887-B. The
tool set is manufactured by the Miller Tool Co. and is available through the dealer tool program. Pre-sized service bushings are available for re­
placement purposes. Only the sun gear bushings are
not serviced. Low cost of the sun gear assembly
makes it easier to simply replace the gear and bush­
ings as an assembly. Heli-Coil inserts are recommended for repairing
damaged, stripped or worn threads in aluminum

parts.
These inserts are available from most automo­
tive jobbers. Stainless steel inserts are preferred. The use of crocus cloth is permissible where neces­
sary, providing it is used carefully. When used on
valves, use extreme care to avoid rounding off sharp
edges.
Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve

bore.

Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts as well.
Lubricate transmission parts with Mopar ATF

Plus,
Type 7176, or Dexron II™ transmission fluid during overhaul and assembly.
Use Ru-Glyde or Door Eze to lubricate clutch pis­
ton seals. Use petroleum jelly to lubricate O-rings and thrust washers. Petroleum jelly can also be used
to hold parts in place during reassembly.

TRANSMISSION
CASE
CLEAN1N8
AND
INSPECTION

Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent. Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear. Do not use shop towels or rags to dry the case
(or any other transmission component) unless
they are made from lint-free materials. Lint will
readily adhere to case surfaces and transmission
components and will circulate throughout the
transmission after assembly. A sufficient quan­
tity of lint can block fluid passages and interfere
with valve body operation. Inspect the case for cracks, porous spots, worn

bores,
or damaged threads. Damaged threads can be repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way into the case. Be sure the screw turns freely.
Remount the case in Repair Stand C-3750-B after
cleaning and inspection.

OVERRUNNING CLUTCH-LOW-REVERSE
DRUM-REAR
SUPPORT OVERHAUL

DISASSEMBLING OVERRUNNING CLUTCH/ LOW-REVERSE DRUM
If the clutch assembly came out with the low-re­
verse drum, thread two clutch cam bolts into the cam. Then lift the cam out of the drum with the bolts (Fig. 29). Rotate the cam back and forth to ease re­
moval if necessary. Remove the clutch roller and spring assembly from the race afterward.
Fig, 29 Removing Overrunning Clutch From Low- Reverse Drum—32RH
CLEANING AND INSPECTION Clean the overrunning clutch assembly, clutch
cam, low-reverse drum and rear support in solvent.
Dry them with compressed air after cleaning. Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring as­ sembly if any rollers or springs are worn or dam­
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse drum if the clutch race,
roller surface or inside diameter is scored, worn or damaged. Do not remove the clutch race from the
low-reverse drum under any circumstances. Re­ place the drum and race as an assembly if either component is damaged.
Examine the rear support carefully for wear,
cracks, scoring or other damage. Be sure the support
hub is a snug fit in the case and drum. Replace the support if worn or damaged.

•

TRANSMISSION
OVERHAUL—32RH
21 - 159 ASSEMBLING OVERRUNNING
CLUTCH/LOW*

REVERSE DRUM (1) Assemble clutch rollers and springs in retainer
if necessary (Fig. 30).
RETAINER

J9121-139

Fig.
30 Overrunning
Clutch
Rollers,
Springs,
Retainer—32RH (2) Install overrunning clutch roller, spring and re­
tainer assembly in clutch cam (Fig. 31).
CLUTCH

ROLLER

ASSEMBLY

CLUTCH
CAM
J9121-138

Fig.
31
Assembling
Overrunning
Clutch
And
Cam-32RH
(3) Temporarily assemble and check overrunning
clutch operation as follows:
(a) Assemble cam and clutch.
(b) Install clutch assembly on low-reverse drum
with twisting motion (Fig. 32).
(c) Install drum-clutch assembly in case and in­
stall clutch cam bolts.
(d) Install rear support and support attaching

bolts.
(e) Check low-reverse drum rotation. Drum
should rotate freely in clockwise direction and
lock when turned in counterclockwise direc­
tion (as viewed from front of case).
LOW-REVERSE
^/

DRUM
CLUTCH

RACE
(ON
HUB OF
DRUM)

OVERRUNNING
CLUTCH
J9121-135

Fig.
32 Temporary
Assemby
Of
Clutch
And
Drum
To

Check
Operation—32RH (4) Note component position for assembly refer­

ence.
Bolt holes in clutch cam are countersunk on
one side, Be sure this side of cam will face rearward
when installed (Fig. 33).
(5) Remove rear support, overrunning clutch and
low-reverse drum. Set components aside for final as­
sembly. If overrunning clutch will be installed

LOW-REVERSE
DRUM
OVERRUNNING

CLUTCH

CAM
ROLLER

AND

SPRING ASSEMBLY

CLUTCH
RACE

HUB OF

LOW-REVERSE
DRUM
J9121-140

Fig.
33
Assembled
Overrunning
Clutch
Components—32RH