DODGE TRUCK 1993 Service Repair Manual

21
- 250
TRANSMISSION 0VERHAUL-42RH
—

Fig.
67
Checking
Rear
Clutch
Pack
Clearance
(15) Coat rear clutch fiber thrust washer with pe­
troleum jelly and install washer over input shaft and into clutch retainer (Fig. 68). Use enough petroleum
jelly to hold washer in place.
(16) Set rear clutch aside for installation during fi­
nal assembly.

PLANETARY GEAR TRAIN AND INTERMEDIATE
SHAFT OVERHAUL

GEARTRAIN DISASSEMBLY (FIG* 69) (1) Remove snap ring, tabbed thrust washer and
thrust plate from front of output shaft. (2) Remove front annulus gear and support assem­
bly. (3) Remove front planetary front thrust washer.
(4) Remove front planetary gear.
(5) Remove front planetary rear thrust washer.
(6) Remove sun gear and driving shell. •

Fig.
68 Installing Rear
Clutch
Thrust Washer—42RH (7) Remove snap ring that retains sun gear in
driving shell and remove sun gear and thrust plates.
Note thrust plate position for assembly reference. (8) Remove tabbed thrust washer from rear plane­
tary gear.
(9) Remove rear planetary gear from rear annulus
gear and remove annulus gear from intermediate
shaft.
(10) Remove snap rings securing annulus gears to
supports. Then separate each gear from support.
PLANETARY GEARTRAIN INSPECTION Clean the planetary components in solvent and dry
them with compressed air. Check sun gear and driving shell condition. Re­
place the gear if damaged or if the bushings are scored or worn. The bushings are not serviceable. Re­
place the driving shell if worn, cracked or damaged.
Replace planetary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace the annu­
lus gears and supports if either component is worn or
damaged.
Inspect the geartrain spacers, thrust plates, snap

rings,
and thrust washers. Replace any part that is worn or damaged. Do not attempt to reuse these

parts.

Inspect the intermediate shaft carefully. Pay par­
ticular attention to the machined bushing/bearing surfaces on the shaft.
Replace the intermediate shaft if any machined
surfaces are scored, pitted, or damaged in any way.
Also replace the shaft if the splines are damaged, or exhibits cracks at any location. Be sure the select spacer groove on the shaft is in good condition. Trial
fit the spacer if necessary.
(11) Install first clutch disc in retainer on top of
bottom pressure plate. Then install a clutch plate fol­ lowed by a clutch disc until entire clutch pack is in­
stalled. 4 clutch discs and 3 metal plates are
required.
(12) Install top pressure plate (Fig. 60).
(13) Install selective snap ring (Fig. 60). Be sure
snap ring is fully seated in retainer groove. (14) Measure clutch pack clearance (Fig. 67).
Clearance should be 0.64 to 1.14 mm (0.025 to 0.045

in.).
If clearance is incorrect, steel plates, discs, snap
ring and pressure plates may have to be changed (Fig. 53).

#
, , . , _
TRANSMISSION 0VERHAUL-42RH
21 - 251

SELECT
FRONT

FIT ANNULUS
PLANETARY SNAP

SNAP
RING RING SUPPORT

SNAP
RING
FRONT

ANNULUS
GEAR
FRONT

PLANETARY THRUST

WASHERS
SUN

GEAR
SUN

GEAR

SPACER
DRIVING SHELL

FRONT
THRUST
PLATE
FRONT

ANNULUS
THRUST

WASHER

DRIVING
SHELL
REAR

THRUST PLATE OVERDRIVE
PISTON
RETAINER INTERMEDIATE
SHAFT THRUST PLATE DRIVING

,
SHELL
CLUTCH
CAM BOLTS
INTERMEDIATE SHAFT
Fig.
69
Transmission
Planetary Gear Train—42RH
J9221-18

PLANETARY
GEARTRAIN
ASSEMBLY
(1) Lubricate intermediate shaft and planetary
components with transmission fluid. Use petroleum
jelly to lubricate and hold thrust washers and plates in position. (2) Assemble rear annulus gear and support if dis­
assembled. Be sure support snap ring is seated and
that shoulder side of support faces rearward.
(3) Install rear thrust washer on rear planetary
gear (Fig. 70). Use enough petroleum jelly to hold
washer in place. Also be sure washer tabs are prop­ erly engaged in gear slots.
(4) Install rear annulus over and onto rear plane­
tary gear (Fig. 70).
(5) Install assembled rear planetary and annulus
gear on intermediate shaft (Fig. 71). Verify that as­
sembly is fully seated on shaft.
(6) Install front thrust washer on rear planetary
gear (Fig. 72). Use enough petroleum jelly to hold
washer on gear.
(7) Install spacer on sun gear (Fig. 73).
(8) Install thrust plate over sun gear and on top of
spacer (Fig. 74). Note that thrust plates are inter­
changeable. Use either plate on sun gear and rear of
driving shell.
REAR

ANNULUS
GEAR

TABBED
THRUST

WASHER

REAR

PLANETARY

J9121-156

Fig.
70
Assembling
Rear
Annulus
And Planetary
Gear-42RH
(9) Insert sun gear into driving shell (Fig. 75).
(10) Hold sun gear in position and install rear
thrust plate. Plate goes over sun gear at rear of driv­ ing shell (Fig. 75).

21

- 252 TRANSMISSION OVERHAUL-42RH
•

REAR
ANNULUS

AND
PLANETARY
GEAR
ASSEMBLY

INTERMEDIATE
SHAFT

J9121-275

Fig.
71 installing
Assembled
Rear
Annulus
And Planetary Gear On
Intermediate
Shaft—42RH
FRONT

TABBED
THRUST

WASHER
REAR

PLANETARY
GEAR
J9121-158

Fig.
72 Installing Rear Planetary Front Thrust
Washer-42RH

SUN
GEAR SUN GEAR

SPACER
J912M59

Fig.
73 Installing Sun Gear Spacer—42RH
(11) Position wood block on bench and support sun
gear on block (Fig. 76). This makes it easier to align
THRUST
PLATE
Fig.
74 Installing
Spacer
And Thrust
Plate
On Sun
Gear-42RH

SUN

DRIVING
GEAR SHELL
REAR

THRUST
PLATE
J9121-162

Fig.
75 Installing Sun Gear And Rear Thrust
Plate
In
Driving
Shell-42RH
and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play check.
SUN
GEAR

DRIVING
SHELL
WOOD

BLOCK

J912M63

Fig.
76 Supporting Sun Gear On
Wood
Block-42RH

•

TRANSMISSION
OVERHAUL-42RH
21 - 253 (12) Align rear thrust plate on driving shell and
install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (Fig. 77).

Fig.
77 Installing Sun Gear
Lock
Ring—42RH

(13) Install assembled driving shell and sun gear
on intermediate shaft (Fig. 78).

Fig.
78 Installing
Assembled
Sun Gear And Driving
Shell
On
Intermediate
Shaft—42RH
(14) Install rear thrust washer on front planetary
gear (Fig. 79). Use enough petroleum jelly to hold
washer on gear and be sure washer tabs are all prop­ erly seated.
(15) Assemble front annulus gear and support if
necessary.
(16) Position thrust plate on front annulus gear
support (Fig. 80). Use liberal quantity of petroleum
jelly to hold plate in place.
(17) Install front planetary gear on intermediate
shaft and in driving shell (Fig. 81).
(18) Install front thrust washer on front planetary
gear (Fig. 81). Use enough petroleum jelly to hold
washer in place on gear and be sure washer tabs are seated.
Fig.
79 Installing Rear Thrust
Washer
On Front
Planetary Gear—42RH

Fig.
80 Installing Thrust
Plate
On Front
Annulus
Support—42RH

Fig.
81 Installing Front Planetary And
Annulus
Gears—42RH

21
- 254
TRANSMISSION OVERHAUL-42RH

• (19) Assemble front annulus gear and support. Be
sure support snap ring is seated. (20) Install front annulus thrust washer (Fig. 82).
Align flat on washer with flat on planetary hub. Also
be sure washer tab is facing forward.
Fig.
82 Installing Front
Annulus
Thrust

Washer-42RH
(21) Install front annulus snap ring (Fig. 83). Use
snap ring pliers to avoid distorting ring during in­
stallation. Also be sure ring is fully seated.
Fig.
83 Installing Front
Annulus Snap Ring—42RH

(22) Install planetary selective snap ring with snap
ring pliers (Fig. 84). Be sure ring is fully seated.
(23) Turn planetary geartain assembly over so
driving shell is facing workbench. Then support
geartrain on wood block positioned under forward
end of output shaft. This is necessary so geartrain
components will move forward for accurate end play check.
(24) Check planetary geartrain end play with
feeler gauge (Fig. 85). Gauge goes between shoulder
on intermediate shaft and end of rear annulus sup­
port.
SELECTIVE

Fig.
84 Installing Planetary Selective
Snap Ring-42RH
(25) Geartrain end play should be 0.12 to 1.22 mm
(0.005 to 0.048 in.). If end play is incorrect, snap ring
(or thrust washers) may have to be replaced. Snap
ring is available in three different thicknesses for ad­
justment purposes.
Fig.
85
Checking
Planetary
Geartrain
End

Play-42RH
FRONT
SERVO
AND
BAND OVERHAUL

FRONT
SERVO DISASSEMBLY
(FIG. 86) (1) Remove small snap ring from servo piston. (2) Remove piston, rod, springs and guide.
(3) Remove and discard servo piston rings and
O-ring.

TRANSMISSION
OVERHAUL-42RH
21 - 255
FRONT BAND AND SERVO INSPECTION
Clean the servo components with solvent and dry
them with compressed air.
Inspect the servo components. Replace the springs
if collapsed, distorted or broken. Replace the guide,
rod and piston if cracked, bent, or worn. Discard the servo snap ring if distorted or warped.
Replace the front band if distorted, the lining is
burned or flaking off, or excessively worn.
Check the servo piston bore for wear. Replace the
piston and rod as an assembly if either part is worn or damaged.
Replace any servo component if doubt exists about
its condition. Do not reuse suspect parts.
PISTON PISTON

ROD
ROD

SNAP
RING
SERVO

PISTON

ROD

GUIDE
PISTON

SEALS

PISTON
ROD

SEAL

PISTON

SPRING

SERVO
ROD
SNAP
GUIDE RING
SEAL J912M72

Fig.
86 Front
Servo
Components—42RH
ASSEMBLING FRONT SERVO PISTON
(1) Lubricate seal rings and O-rings with petro­
leum jelly. Lubricate other servo parts with trans­
mission fluid.
(2) Install new O-ring on servo piston rod.
(3) Install new seal on piston rod guide and install
new seal rings on piston. (4) Assemble rod, piston, servo springs and snap
ring (Fig. 86).

REAR
SER¥0 AND BAND OVERHAUL

REAR SERVO PISTON DISASSEMBLY (1) Remove seal from servo piston. Note which way
seal lip faces for assembly reference.
(2) Compress cushion spring in vise only enough to
allow piston plug snap ring removal (Fig. 87). Use
wood block between vise jaws and end of piston plug
to keep plug aligned and in position. (3) Remove snap ring from end of piston plug (Fig.

87).
(4) Open vise and remove wood block, piston plug,
cushion spring and servo piston.

SMALL
WOOD BLOCK

PISTON PLUG

SNAP
RING
SNAP

RING

PLIERS

J9121-174

Fig.
87 Removing/lnstailing
Servo
Piston
Piug
Snap
Ring—42RH

REAR SERVO INSPECTION Clean the servo components (Fig. 88) with solvent
and dry them with compressed air.
Check rear band condition. Replace the band if dis­
torted, the lining is burned or flaking off, or the lin­ ing is excessively worn. Check the band pivot and
reaction pins. Minor pin scoring can be cleaned up
with crocus cloth. However, replace the pins if worn, severely scored, or cracked. Replace the pin O-rings.
Inspect the servo components. Replace the servo
and cushion springs if collapsed, distorted or broken.
SPRING
RETAINER
SERVO
SPRING

PISTON PLUG

CUSHION
SPRING SERVO
SNAP
RING

PISTON PLUG

SNAP
RING

SERVO

PISTON
J9121-173

Fig.
88 Rear
Servo
Components—42RH

21
- 256
TRANSMISSION OVERHAUL-42RH

Replace the plug or piston if cracked, bent, or worn.
Discard the servo snap ring and spring retainer if
distorted or warped. If doubt exists about the condition of any servo
component, replace it. Do not reuse suspect parts.
ASSEMBLING REAR SERWO PISTON (1) Assemble piston plug, cushion spring and pis­
ton (Fig. 88). (2) Compress cushion spring in vise and install pis­
ton plug snap ring (Fig. 87).
(3) Install new seal on piston. Be sure seal lip is
toward servo bore (Fig. 89). (4) Lubricate piston seal with petroleum jelly. Lu­
bricate other servo parts with transmission fluid.

BE
SURE

SEAL
LIP

IS
TOWARD

SERVO
BORE
REAR

SERVO

PISTON

J9121-175

Fig.
89 installing Rear
Servo
Piston
Seal

VALVE
BODY
SERVICE
AND ADJUSTMENT
WALWE
BODY MAIN COMPONENT
DISASSEMBLY

CAUTION:
Do not
clamp
any
valve body compo­
nent
in a
vise. This
practice
can
damage
the
com­
ponent
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
reference
as
they
are
removed.
Do
not allow
them
to
become intermixed.

(1) Remove boost valve cover (Fig. 90).
(2) Remove boost valve retainer, valve spring and
boost valve (Fig. 91). (3) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 92).
(4) Remove E-clip that secures throttle lever in
manual lever (Fig. 93). (5) Lift and rotate manual lever far enough to
clear detent housing.
IK)
O °o O OOO

UPPER
HOUSING
J9321-126
Fig.
90
Boost
Valve
Cover
Location—42RH

BOOST VALVE
INSTALLED
LOCATION
SPRING BOOST AND VALVE BOOST
VALVE SPRING VALVE
RETAINER COVER

SCREWS

J9321-127

Fig.
91
Boost
Valve
Components
SPECIAL

TOOL
6583

DETENT BALL AND SPRING HOUSING
J9321
-121
Fig.
92
Securing
Detent
Ball
And
Spring

•

TRANSMISSION
0VERHAUL-42RH
21 - 257

THROTTLE
LEVER

AAANUAL
LEVER
E-CLIP
J9321-138

Fig. 93 Removing Throttle Lever
E-Clip

(6) Remove retaining tool and remove detent ball
and spring (Fig. 94). AAANUAL

LEVER

DETENT
HOUSING

DETENT
BALL.

AND
SPRING
J9321-139

Fig.
94 Detent Bali 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).
AAANUAL
LEVER AND
PARK ROD

ASSEMBLY

MANUAL LEVER
WASHER
J932M40

Fig.
95 Manual
Lever
Removal—42RH (8) Remove throttle lever from valve body housing
(Fig. 96).
THROTTLE

LEVER

J932M41

Fig.
96
Throttle
Lever
Removal—42RH (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—42RH
(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.
(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).
(14) Remove screws attaching solenoid assembly to
valve body lower housing and remove solenoid and connector assembly (Fig. 101).

21
- 258
TRANSMISSION 0VERHAUL-42RH

•

PRESSURE

REGULATOR
VALVE SPRING
ADJUSTING
SCREW

BRACKET

SWITCH VALVE

SPRING
LINE PRESSURE
ADJUSTING SCREW
J9121-512

Fig.
98 Adjusting
Screw
Bracket And
Spring

Removal—42RH

SOLENOID
CONNECTOR
3-4

ACCUMULATOR HOUSING

a=J932M43

Fig.
99
Solenoid
Connector
Position—42RH
SOLENOID
WIRES
(NOTE
WIRE

ROUTING)
s\^t%U^r
^^^^

Fig.
100
Solenoid
Wire
Routing—42RH
SOLENOID

ATTACHING
SCREWS
LOWER
HOUSING
SOLENOID
ASSEMBLY
J932M44

Fig.
101
Solenoid
Assembly
Removal—42RH (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—42RH
(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).
(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.

(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.

TRANSMISSION
0VERHAUL-42RH
21 - 259

LOWER

HOUSING
CLUTCH

VALVE
AND
SPRING
3-4

SHIFT

VALVE
AND

SPRING
PRESSURE

CLUTCH
REGULATOR
VALVE VALVE
PLUG
SPRING
J9321-146

Fig.
103
Clutch
Valve And 3-4 Shift Vaive
Locations—42
RH
BOOST

.VALVE
TUBE
LOWER

HOUSING

UPPER

HOUSING
DISENGAGE

THIS
END OF
TUBE
FIRST
J9321-147

Fig.
104
Boost
Valve Tube Removal—42RH (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.
(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.
LOWER

HOUSING
VALVE

BODY

SCREWS
(13)
S
^ c
TUBE
BRACE
J9321-148

Fig.
105 Valve
Body
Screw
And Tube
Brace
Location—42RH

OVERDRIVE

SEPARATOR
PLATE
TRANSFER

PLATE
AND
UPPER

HOUSING

LOWER

HOUSING
J9321-149

Fig.
106
Lower
Housing
Removal—42RH
UPPER

HOUSING

TRANSFER

PLATE

J932M52

Fig.
107
Removing
Transfer
Plate
From Upper
Housing—42RH

(25) Remove rear clutch check ball from transfer
plate. Note check ball location for assembly
ref­
erence before removing it (Fig. 110).