DODGE TRUCK 1993 Service Repair Manual

21
- 310
TRANSMISSION 0VERHAUL-46RH

• plate carefully. Be sure all fluid passages are clean
and clear. Check condition of the upper housing and
transfer plate check balls as well. The check balls and ball seats must not be worn or damaged.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with

use.
If the valve body functioned correctly when new,
it will continue to operate properly after cleaning
and inspection. It should not be necessary to replace
a valve body assembly unless it is damaged in han­
dling.

VALWE
BODY BEASSEMBLY

CAUTION; Do not
force valves
or
plugs
into place
during reassembly.
If the
valve body bores, valves

and
plugs
are
free
of
distortion
or
burrs,
the
valve
body
components should
all
slide into place easily.
In addition,
do not
overtighten
the
transfer
plate

and
valve body screws during reassembly. Over­
tightening
can
distort
the
housings
resulting
in
valve sticking,
cross
leakage
and
unsatisfactory
op­

eration. Tighten valve body screws
to
recom­ mended torque only.
Lower Housing Assembly (Fig.
116)
(1) Lubricate valves, springs, and the housing
valve and plug bores with Mopar ATF Plus, or
Dexron II® transmission fluid. (2) Install 3-4 timing valve spring and valve in
lower housing. (3) Install 3-4 shuttle valve in lower housing.
Press valve inward and install E-clip on end of valve
to secure it in housing.
(4) Install 3-4 shuttle valve spring and throttle
plug in housing. (5) Install timing valve end plate. Tighten end
plate screws to 4 N»m (35 in. lbs.) torque.
(6) Install 3-4 shift valve and spring.
(7) Install converter clutch valve, spring and plug.
(8) Install converter clutch timing valve and
spring.

3-4 Accumulator
Assembly
(Fig.
117) (1) Lubricate accumulator piston, seals and hous­
ing piston bore with ATF Plus, or Dexron II®. (2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end plate on housing.

Transfer Plate Assembly
(1) Install rear clutch check ball in transfer plate
(Fig. 110). (2) Install filter screen in upper housing separator
plate (Fig. 109). (3) Align and position upper housing separator
plate on transfer plate (Fig. 109).
(4) Install brace plate (Fig. 108). Tighten brace at­
taching screws to 4 Nnn (35 in. lbs.) torque. (5) Install remaining separator plate attaching
screws. Tighten screws to 4 N*m (35 in. lbs.) torque.

SHIFT
VALVE
END PLATE
2-3
SHIFT

VALVE AND
SPRING
SHUTTLE VALVE

SECONDARY
SPRING,
GUIDES,
E-CLIP

1-2
SHIFT

CONTROL VALVE AND SPRING
REGULATOR VALVE
END PLATE SHUTTLE VALVE

COVER

SLEEVE

REGULATOR
VALVE
THROTTLE

PRESSURE
PLUG
RETAINER VALVE

SPRING
2-3
SHIFT

VALVE GOVERNOR PLUG
LINE

PRESSURE

ADJUSTING*
SCREW
ADJUSTING

SCREW

BRACKET
SHUTTLE VALVE
PLUG
(ALUM.)

GOVERNOR VALVE END PLATE
AAANUAL LEVER DETENT BALL
AND SPRING

J9221-21 E
w

00

o
z
m
30
Fig. 118 Upper Housing Components—46RH
Valve
Body (Alum.
Indicates
Aluminum
Part)

21
- 312 TRANSMISSION OWERHAUL-46RH

•
Assembling
Upper
And
Lower
Housings

(1) Position upper housing so internal passages
and check ball seats are facing upward. Then install
check balls in housing (Fig. 111). Seven check balls are used. The single large check ball is approxi­
mately 8.7 mm (11/32 in.) diameter. The remaining 6
check balls are approximately 6.3 mm (1/4 in.) in di­ ameter.
(2) Position transfer plate assembly on upper hous­
ing (Fig. 119).
(3) Position lower housing separator plate on
transfer plate (Fig. 119).

TRANSFER
UPPER PLATE HOUSING
J932M59
Fig. 119 Lower Housing Separator Plate Installation—46RH
(4) Install lower housing on assembled transfer
plate and upper housing (Fig. 120).

(5)
Install and start valve body screws by hand.
Then tighten screws evenly to 4 N*m (35 in. lbs.)
torque. Start at center and work out to sides when
tightening screws. Fig. 120 Assembling Valve Body Upper And Lower
Housings—46RH
Upper
Housing
Valve
And
Plug
Installation
(Figs.
114,111,

118)

(1) Lubricate valves, plugs, springs with Mopar
ATF Plus transmission fluid.
(2) Assemble regulator
valve
line pressure plug,
sleeve, throttle plug and spring. Insert assembly in
upper housing and install cover plate. Tighten cover
plate screws to 4 N»m (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install shift valve cover plate. (6) Install shuttle valve as follows: (a) Insert plastic guides in shuttle valve second­
ary spring and install spring on end of valve.
(b) Hold shuttle valve in place.
(c) Compress secondary spring and install E-clip
in groove at end of shuttle valve. (d) Verify that spring and E-clip are properly
seated before proceeding. (7) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N®m (35 in. lbs.) torque.
(8) Install 1-2 and 2-3 valve governor plugs in
valve body. (9) Install shuttle valve primary spring and throt­
tle plug. (10) Align and install governor plug cover. Tighten
cover screws to 4 N#m (35 in. lbs.) torque.
(11) Install manual valve.
(12) Install throttle valve and spring.
(13) Install kickdown valve, and detent. (14) Install regulator valve.
(15) Install switch valve.

Boost
Valve
Tube
Installation
(1) Position valve body assembly so lower housing
is facing upward (Fig. 121). (2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Position tube behind tube brace (Fig. 121).
(4) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 121).
(5) Seat each end of tube in housings.
3-4 Accumulator
Installation
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 122). (2) Loosely attach accumulator housing with right-
side screw (Fig. 122). Install only one screw at this
time as accumulator must be free to pivot upward for ease of installation.
(3) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(4) Swing accumulator housing upward over valve
springs and plug.
(5) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure

•

TRANSMISSION
OVERHAUL-46RH
21 - 313

TUBE
BRACE
UPPER
LOWER
HOUSING PORT
J932M62

Fig.
121
Boost
Valve
Tube Installation—46RH
springs and clutch valve plug are properly seated (Fig. 123).

RIGHT-SIDE
SCREW

3-4 ACCUMULATOR
Fig.
122 Installing Converter
Clutch
And 3-4 Shift
Valve
Springs—46RH

CLUTCH ACCUMULATOR
VALVE PLUG
BOSS
J9321-161

Fig.
123 Seating 3-4
Accumulator
On
Lower
Housing—46RH
(6) Attach solenoid case connector to 3-4 accumula­
tor with shoulder-type screw. Connector has small lo­
cating tang that fits in dimple at top of accumulator
housing (Fig. 124). Seat tang in dimple before tight­ ening connector screw.
(7) Install solenoid assembly and gasket. Tighten
solenoid attaching screws to 8 N*m (72 in. lbs.)
torque.

SOLENOID

CASE
CONNECTOR
Fig.
124
Solenoid
Connector
Installation—46RH
(8) Verify that solenoid wires are properly routed
(Fig. 125). Solenoid wires must be clear of rear
band lever, manual lever and park rod.

Fig.
125
Solenoid
Wire
Routing—46RH

Valve
Body
Final
Assembly
And
Adjustment
(1) Insert manual lever detent spring in upper
housing.

21
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TRANSMISSION
OVERHAUL-46RH
—
•

Fig.
126 Manual And
Throttle
Lever
Alignment
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting. The 33.4 mm (1-5/16 in.) setting is an approxi­
mate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa). Turning the adjusting screw counterclockwise in­
creases pressure while turning the screw clockwise
decreases pressure.

Fig.
127
Line
Pressure
Adjustment

Throttle
Pressure
Adjustment Insert Gauge Tool C-3763 between the throttle le­
ver cam and the kickdown valve stem (Fig. 128).
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.
(2) Position line pressure adjusting screw in ad­
justing screw bracket.
(3) Install spring on end of line pressure regulator
valve. (4) Install switch valve spring on tang at end of
adjusting screw bracket. (5) Position adjusting screw bracket on valve body.
Align valve springs and press bracket into place. In­ stall short, upper bracket screws first and long bot­
tom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket
screws to 4 N*m (35 in. lbs.) torque.
(6) Install throttle lever in upper housing. Then in­
stall manual lever over throttle lever and start man­
ual lever into housing.
(7) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with Re­
tainer Tool 6583 (Fig. 92). (8) Align manual lever with detent ball and man­
ual valve. Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove de­
tent ball retainer fool after lever is seated.
(9) Then Install manual lever seal, washer and
E-clip.
(10) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly. (11) Verify that throttle lever is aligned with end
of kickdown valve stem and that manual lever arm
is engaged in manual valve (Fig. 126).
(12) Install boost valve, valve spring, retainer and
cover plate. Tighten cover plate screws to 4 N»m (35
in. lbs.) torque.
(13) Obtain new fluid filter for valve body but do
not install filter at this time.
(14) If line pressure and/or throttle pressure ad­
justment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as
described in Valve Body Control Pressure Adjust­
ment procedure.

VALVE
BODY
CONTROL
PRESSURE

ADJUSTMENTS

There are two control pressure adjustments on the
valve body which are, line pressure and throttle pres­
sure.

Line and throttle pressures are interdependent be­
cause each affects shift quality and timing. As a re­
sult, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first
and throttle 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. 127). Distance should be 33.4 mm (1-5/16 in.).

•

TRANSMISSION
OVERHAUL-46RH
21 - 315
The kickdown valve spring must be fully com­
pressed and the kickdown valve completely bot­
tomed to obtain correct adjustment.
Fig.
128
Throttle
Pressure
Adjustment

TRANSMISSION ASSEMBLY

Assembly
Tips
Do not allow dirt, grease, or foreign material to en­
ter the case or transmission components during as­ sembly. Keep the transmission case and components
clean. Also make sure the tools and workbench area
used for reassembly operations are equally clean.
Shop towels used for wiping off tools and your
hands must be made from lint free materials. Lint
will stick to transmission parts and could interfere
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components
with Mopar ATF Plus or Dexron II™ during reassem­
bly. Soak clutch discs in transmission fluid before in­ stallation.
Use Ru-Glyde, Door-Eze, or petroleum jelly on
seals and O-rings to ease installation. Petroleum
jelly can also be used to hold thrust washers and plates in position during assembly operations. How­ever, do not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of lubricants can eventually block or re­ strict fluid passages and valve operation. Use petro­
leum jelly only.
Do not force parts into place. The transmission
components and sub-assemblies are easily installed
by hand when properly aligned. If a part seems diffi­ cult to install, it is either misaligned or incorrectly
assembled. Verify that thrust washers, thrust plates
and seal rings are correctly positioned. These parts
will prevent proper assembly is mispositioned (or "left out" by accident).
The planetary geartrain, front/rear clutch assem­
blies and oil pump are all much easier to install
when the transmission case is upright or as close to
this position as possible. Either tilt the case upward with wood blocks, or cut a hole in the bench large
enough for the output shaft and rear support. Then
lower the shaft and support into the hole and support
the rear of the case directly on the bench.

TRANSMISSION ASSEMBLY PROCEDURE
(1) Lubricate rear servo piston seal with petroleum
jelly, or Door Eze. Lubricate servo bore in case with transmission fluid.
(2) Install rear servo piston in case. Position piston
at slight angle to bore and insert piston with twist­
ing motion (Fig. 129).

Fig.
129 Installing Rear
Servo
Piston—46RH
(3) Install rear servo spring and retainer in case
bore (Fig. 130). Be sure spring is seated on piston.

Fig.
130 Installing Rear
Servo
Piston
Spring
And Retainer—46RH (4) Compress rear servo piston with C-clamp or
Valve Spring Compressor C-3422-B and install servo
piston snap ring (Fig. 131).
(5) Install new gasket at rear of transmission case.
Use petroleum jelly to hold gasket in place. Be sure
to align governor feed holes in gasket with feed passages in case (Fig. 132). Install gasket before

21
- 31S
TRANSMISSION
0VERHAUL-46RH

Fig.
131 Installing Rear
Servo
Snap
Ring—46RH
overdrive piston retainer. Center hole in gasket
is smaller than retainer and cannot be installed over retainer.
Fig.
132 Installing
Case
Gasket—46RH
(6) Install overdrive piston retainer. Be sure gover­
nor tube bores in retainer are aligned with governor
feed passages in gasket and case (Fig. 133). Install and tighten retainer bolts to 17 N»m (13 ft. lbs.)
torque.
(7) Install overrunning clutch components if not
yet installed. Refer to Overrunning Clutch Overhaul in this section if necessary.
(8) Position rear band and link in case (Fig. 134).
Be sure notched side of link faces away from
band. •

Fig.
133 Installing Overdrive
Piston
Retainer—46RH
Fig.
134 Installing Rear
Band
And
Link—46RH
(9) Install low-reverse drum (Fig. 135). Slide drum
through rear band, onto rear support hub and into engagement with overrunning clutch race.
(10) Install snap ring that secures low-reverse
drum to rear support hub (Fig. 136).
(11) Insert band reaction pin part way case and
band link (Fig. 137).

•

Fig.
136 Installing
Low-Reverse
Drum
Snap
Ring-46RH
(12) Install rear band adjusting lever, strut and re­
action lever (Fig. 138). Be sure levers and strut are
aligned and engaged before seating band reaction pin
in case.
(13) Lubricate front servo piston components and
servo bore in case with transmission fluid.
(14) Install front servo piston in bore. Carefully
"run" small, suitable tool around piston ring to press
it back into groove and ease installation (Fig. 139).
Rotate piston into bore at same time. Rock piston slightly to ease piston ring past snap ring groove and
into bore. (15) Bottom front servo piston in bore and install
servo spring. (16) Install front servo piston rod guide as follows:
TRANSMISSION
0VERHAUL-4SRH
21 - 317

Fig,
137 Installing Rear
Band
Reaction
Pin—46RH

ADJUSTING ADJUSTING
J9121-92

Fig.
138 Rear
Band
Levers
And Strut—46RH (a) Place Tool SP-5560 (or similar size tool) on
guide and position C-clamp on tool and case (Fig.
140).

(b) Slowly compress rod guide while simulta­
neously easing seal ring into bore with suitable
tool. (17) Install rod guide snap ring (Fig. 140).
(18) Position front band lever in case and over
servo rod guide. Then install front band lever pin in
case and slide it through lever.
(19) Coat threads of front band lever pin access
plug with sealer and install it in case. Tighten plug to 17 N-m (13 ft. lbs.) torque.

21
- 318
TRANSMISSION
0WERHAUL-46RH

Fig.
140 Installing Front
Servo
Rod
Guide
And
Snap
Ring-46RH
(20) Install assembled output shaft and planetary
gear components (Fig. 141). Support shaft care­
fully during installation. Do not allow shaft
bearing/bushing surfaces to become nicked or scratched. (21) Lubricate intermediate shaft thrust plate with
petroleum jelly and install plate on shaft pilot hub (Fig. 142). (22) Check input shaft front seal rings, fiber thrust
washer and rear seal ring (Fig. 143). Be ends of rear seal ring are hooked together and diagonal cut ends
of front seal rings are firmly seated against each other as shown. Lubricate seal rings with petroleum
jelly after checking them.
(23) Assemble front and rear clutches (Fig. 144).
Align lugs on front clutch discs. Mount front clutch •

ASSEMBLY
J9121-508

Fig.
141 Installing
Intermediate
Shaft And Planetary Geartrain—46RH

Fig.
142 Installing
Intermediate
Shaft Thrust Plate-46RH on rear clutch. Turn front clutch retainer back and
forth until front clutch discs are fully seated on rear clutch splined hub.
(24) Install intermediate shaft thrust washer in
hub of rear clutch retainer (Fig. 145). Use petroleum
jelly to hold washer in place. Position washer so grooves are facing outward. Washer only fits one
way in clutch retainer hub.
(25) Place transmission case in upright position, or
place blocks under front end of transmission repair stand to tilt case rearward. This makes it easier to
install front/rear clutch assembly. (26) Align discs in rear clutch. Then install and
engage assembly in front planetary and driving shell (Fig. 146). Turn clutch retainers back and forth until
both clutches are seated. (27) Slide front band over front clutch retainer and
install front band strut and anchor (Fig. 147).

•

TRANSMISSION
0VERHAUL-46RH
21 - 319
Fig. 143 input Shaft Seat Ring And Thrust Washer Installation—46RH
Fig. 144 Assembling Front And Rear Clutches-46RH (28) Tighten front band adjusting screw until band
is tight on clutch retainer. Verify that front/rear
clutch assembly is still properly seated before tight­
ening band.
(29) Install oil pump Pilot Studs
C-3288-B
in case
(Fig. 148). Fig. 145 Installing intermediate Shaft Thrust

Washer-46RH

Fig. 146 Installing Front/Rear Clutch Assemblies—46RH (30) Install new oil pump gasket on pilot studs and
seat it in case. Be sure gasket is properly aligned
with fluid passages in case (Fig. 148). (31) Check seal rings on reaction shaft support. Be
sure rings are hooked together correctly. Also be sure
fiber thrust washer is in position (Fig. 149). Use pe­
troleum jelly to hold washer in place if necessary.