1993 DODGE TRUCK Service Repair Manual

HYDRAULIC FLOW IN DRIVE THIRD GEAR (42RH/46RH)

HYDRAULIC FLOW IN DRIVE FOURTH GEAR OVERDRIVE (42RH/46RH)

GOVERNOR
VALVE

J9321-203
r3

21
-
130
IN-VEHICLE
SERVICE-~32RH/36RH/37RH/42RH/4iRH

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

INDEX

page
Aluminum Thread Repair
141
Checking
Fluid
Level
130
Extension Housing Bushing
and
Output
Shaft
Bearing
Service-32RH/36RH/37RH
... .
135

Extension Housing Yoke Seal Replacement
....
135

Fluid
and Filter
Change
130

Front
Band
Adjustment
133

Gearshift Linkage
Adjustment
130

Governor
and
Park Gear Service—
32RH/36RH/37RH
137

Governor
and
Park Lock Service—42RH/46RH
.
138

CHECKING
FLUID LEVEL

(1) Position vehicle
on
level surface. This
is ex­

tremely important
for
accurate check.
(2)
Apply parking brakes
and run
engine
at
curb
idle speed.
(3)
Shift transmission momentarily into
all
gear
ranges. Then shift back
to
Neutral.
(4)
Clean
top of
filler tube
and
dipstick
(to
avoid
dirt entry)
and
check fluid level. Correct level
is as

follows:
(5)
Be
sure fluid
is at
normal operating tempera­
ture (180°F). Correct level
is
between "Maximum Level
Hot"
and
"Add"
marks (crosshatched area)
on

dipstick. (6)
If
fluid level
is
low,
add
only enough fluid
to

correct level.

CAUTION:
Do not
overfill
the
transmission. Overfill­ing
will
force fluid
out
the
pump vent which
can
be

mistaken
for
a
pump seal leak. Overfilling
will
also

cause
fluid aeration
and foaming
when
the
excess
fluid
is
picked
up
and
churned
by
the
gear train. Aeration
will
reduce fluid
life
significantly.

FLUID
AND
FILTER
CHANGE
Normal Change
Interval
The fluid
and
filter should
be
changed
(and the

bands adjusted)
at
recommended maintenance inter­
vals.
Or
whenever
the
transmission
has
been disas­sembled
for
any
reason.

Recommended Fluid
The recommended
(and
preferred) fluid
for

Chrysler automatic transmissions
is
Mopar
ATF

Plus,
type
7176.
Use
Mopar Dexron
II
only when
ATF Plus
is not
readily available.
page
Park Lock
Service-32RH/36RH/37RH
. 138

Park/Neutral Position Switch
134
Rear
Band
Adjustment
133

Speedometer Service
134

Transmission Cooler Service
140
Transmission
Throttle
Cable
Adjustment-
Cummins Diesel Engine
132

Transmission
Throttle
Cable
Adjustment-
Gas
Engines
131

Valve Body
Control
Pressure Adjustments
.....
140

Valve Body Service
138

Severe Usage Change
Interval
Under severe usage,
the
fluid
and
filter should
be

changed
and the
bands adjusted
at
12,000 mile (19,000
km)
intervals.
Severe usage
is
defined
as:

• More than half
of
vehicle operation occurs
in

heavy city traffic during
hot
weather
at
ambient
temperatures above
90°
F.
• Vehicle
is
used
for
Taxi, Police, Limousine,
or
sim­
ilar commercial operations.
• Vehicle
is
used
for
trailer/boat towing
or
heavy
load hauling. When
the
factory fluid
is
drained, refill
the
trans­
mission with Mopar
ATF
Plus, type
7176
fluid.
Mo­

par Dexron
II
can
be
used
if
ATF
Plus
is
not
readily available.

FLUID
AND
FILTER
REPLACEMENT
PROCEDURE
(1) Raise vehicle, remove
oil pan
and
drain fluid.
(2) Remove filter screws
and
remove filter.
(3) Position
new
filter
on
valve body
and
install fil­
ter screws finger tight. (4) Tighten filter screws
to 4
N*m (35
in.
lbs.)
with
torque wrench.
(5) Position
new
gasket
on oil pan
and
install
pan

on transmission. Tighten
pan
bolts
to 17
N»m
(150

in.
lbs.)
torque. (6) Lower vehicle
and
refill transmission with rec­
ommended fluid.

GEARSHIFT LINKAGE ADJUSTMENT
Check linkage adjustment
by
starting
the
engine
in Park
and
Neutral. Adjustment
is
OK
if
the
engine starts only
in
park
and Neutral. Adjustment
is
incorrect
if
the
engine starts
in one

but
not
both positions. If
the
engine starts
in
any
position other than Park
or Neutral,
or if
the
engine will
not
start
at
all,
the

park/neutral position switch
may
be
faulty.

•

IN-VEHICLE
SERVICE-32RH/36RH/37RH/42RH/46RH
21 - 131

Fig.
1
Column
Gearshift
Linkage
LINKAGE
ADJUSTMENT
PROCEDURE

Do
not
attempt
linkage
adjustment
if any
compo­
nents
are
worn
or
damaged.
If
either linkage
rod

must
be
disconnected,
the plastic
grommet secur­
ing
the rod in the
torque shaft lever must
be re­
placed. Disconnect
the rod
with
a pry
tool.
Pry
only where
the
grommet
and rod
attach
and not on

the
rod
itself.
Then
cut
away
the old
grommet.
Use

pliers
to
snap
the new
grommet into
the
lever
and

to snap
the rod
into
the
grommet.
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Check condition
of
shift rods, control lever,
bushings, washers
and
torque shaft
(Fig.
1). Tighten,
repair,
or
replace worn
or
damaged parts. (4) Loosen shift rod adjusting swivel lock screw.
Be

sure swivel turns freely
on rod.
(5) Verify that valve body shift control lever
is in

Park detent. Move lever fully rearward
to
check. (6) Adjust swivel position
(on the
shift rod)
to a ob­

tain free
pin fit in
torque shaft lever
(Fig. 1).
Then
tighten swivel lock screw
to 10 N»m (90 in. lbs.)
torque.
(7) Check adjustment
by
starting engine
in
Park
and Neutral. Engine should start
in
these positions

only. If
engine starts
in any
position other than
Park
or
Neutral, adjustment
is
incorrect
or

park/neutral position switch
is
faulty.
TRANSMISSION
THROTTLE
CABLE

ADJUSTMENT-GAS
ENGINES
(1)
Turn ignition
key to OFF
position.

(2)
Remove
air
cleaner.

(3)
Position 2.8
-
3.04
mm
(0.110
-
0.120
in.)
thick
spacer between idle stop
and
throttle lever
on
throt­
tle body.
Use
appropriate thickness feeler gauges,
or
shim stock
as
spacer
(Fig. 2).
Fig.
2
Positioning
Spacer
Between
Throttle
Stop

And
Lever
(Gas
Engine)

(4) Press cable lock button
to
release cable
(Fig. 3).

21 - 132
IN-VEHICLE
SERVICE-32RH/36RH/37RH/42RH/46RH

•
IDLE STOP

ADJUSTMENT
• —/

SPACER (USE
Hk±s

FEELER
GAUGES
/o)

OR SHIM STOCK)



THROTTLE BODY LEVER TRANSMISSION
THROTTLE CABLE
TORQUE

SHAFT

BRACKET.
CABLE

RETURN
SPRING
^
CABLE

CONDUIT

CABLE
^1

BUTTON
1
CABLE
\>

WIPER
J932M84

Fig.
3
Throttle
Cable Attachment At
Engine
(Gas
Engine)
(5) Pull cable conduit toward rear of vehicle until
wiper is completely retracted into end of conduit fit­
ting (Fig. 3). Then release cable lock button. (6) Raise vehicle for access to transmission throttle
valve lever (Fig. 4).
(7) Rotate throttle valve lever toward front of ve­
hicle until ratcheting sound (from cable) stops.

CAUTION:
Do not
rotate
the
throttle
valve
lever
be­

yond
the
idle
stop.
The
lever,
valve
and
manual
le­

ver
shaft
will
be
damaged
if
rotated
too far.
(8) Remove spacer and check cable adjustment.
Throttle valve lever should begin to move at same
time lever on MPI throttle body moves off idle posi­
tion.
(9) Lower vehicle.
(10) Install air cleaner.

TRANSMISSION
THROTTLE
CABLE

ADJUSTMENT-CUMMINS
DIESEL
ENGINE
A cable is used to operate the transmission throttle
valve on models with a Cummins diesel engine. Ca­
ble adjustment is controlled by a locking pawl on the cable sheath (Fig. 5). The rear of the cable is connected to the transmis­
sion throttle valve lever. The forward end of the ca­
ble is attached to a pin on the engine throttle cam
RETURN

SPRING
/

BRACKET
^

CABLE

BRACKET
THROTTLE

VALVE
LEVER

(ROTATE
LEVER
IN
DIRECTION
OF
ARROW

FOR
ADJUSTMENT)
THROTTLE

VALVE
CABLE
J9221-64

Fig.
4
Throttle
Cable Attachment At
Transmission
(Gas
Engine)

(Fig. 6). Rotation of the throttle cam (by the engine
throttle cable), actuates the cable and throttle valve lever for downshifts. A 4.57 mm (0.180 in.) diameter gauge is needed
to check and adjust the throttle valve cable on diesel models. Use a micrometer and inside cali­

pers,
a drill of the correct diameter, or fabricate a gauge from metal or aluminum stock. (1) Run engine until it reaches normal operating
temperature.
(2) Verify that engine hot idle speed is within
specifications. Adjust hot idle rpm if necessary.
(3) Check cable adjustment with gauge as follows: (a) Verify that throttle lever is seated against
low idle stop screw (with accelerator pedal fully re­ leased).
(b) Check clearance between rear of cable actuat­
ing pin and end of slot in throttle valve cable (Fig.
6).

(c) Clearance should be 4.57 mm (0.180 in.) as
measured with gauge. (d) If adjustment is OK, no further action is re­
quired. However, if clearance is greater or less
then specified, adjust cable as described in follow­ ing steps.

•

IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH
21 - 133 (4) Lift and release cable locking pawl (Fig. 7).
(5) Insert gauge between cable actuating pin and
end of slot in cable. (6) Slide cable forward or rearward to obtain spec­
ified clearance between pin and cable slot.
(7) Press cable locking pawl downward until it
snaps into locked position.
(8) Check cable adjustment one more time before
moving vehicle. This avoids misadjustment caused by
a shift in component position during adjustment pro­
cedure.
THROTTLE
TRANSMISSION
CAM
THROTTLE

VALVE
i j
/\&s/,

CABLE

m

ENGINE

THROTTLE
CABLE CABLE

LOCK PAWL
J9121-533

Fig.
5
Transmission
Throttle
Cable
Attachment—Diesel
Engine

4.57
MM

(0.180
IN.) GAUGE

J9121-534

Fig.
6
Transmission
Throttle
Cable
Adjustment—Diesel
Engine
FRONT BAND ADJUSTMENT

The front (kickdown) band adjusting screw is at the
left side of the case above the manual valve and
throttle valve levers (Fig. 8). (1) Raise vehicle.
(2) Loosen band adjusting screw locknut. Then
back locknut off 4-5 turns. Also be sure adjusting screw turns freely in case. Lubricate screw threads if
necessary. (3) Tighten band adjusting screw to 8 Nrm (72 in.
J9121
-535

Fig.
7
Transmission
Throttle
Cable
Locking
Pawl
Position—Diesel
Engine
lbs.) torque. If Adapter Extension C-3705 must be
used to reach adjuster screw, tighten screw to only 5 N»m (47-50 in. lbs.) torque.
(4) Back off adjusting screw 2-1/2 turns on all
transmission models. (5) Hold adjuster screw in position with backup
wrench. Then tighten locknut to 41 N»m (30 ft. lbs.)
torque. (6) Lower vehicle.
TO COOLER
KICKDOWN BAND ADJUSTING SCREW
GEARSHIFT CONTROL LEVER
RH256

Fig.
8 Front (Kickdown)
Band
Adjustment
Screw
Location
REAR
BAND ADJUSTMENT

The transmission oil pan must be removed for ac­
cess to the rear band adjusting screw. (1) Raise vehicle.
(2) Remove transmission oil pan and drain fluid.
(3) Loosen band adjusting screw locknut 5-6 turns.
Be sure adjusting screw turns freely in lever. Lubri­
cate screw threads if necessary. (4) Tighten adjusting screw to 8 Nnn (72 in. lbs.)
torque (Fig. 9). (5) Complete band adjustment as follows:
• On 32RH/42RH, back off adjusting screw four

turns.

21
- 134
IN-WEHiCLE SER¥iCE-32RH/3IRH/37RH/42RH/46RH

• • On 36RH/37RH746RH, back off adjusting screw
two turns. (6) Hold adjusting screw in place with backup
wrench. Then tighten locknut to 34 N*m (25 ft. lbs.) torque.
(7) Position new gasket on oil pan and install pan
on transmission. Tighten pan bolts to 17 N»m (13 ft.
lbs.) torque.
(8) Lower vehicle and refill transmission with Mo­
par ATF Plus, type 7176, or Dexron II™ fluid.
Fig. § Rear Band Adjustment Screw Location

SPEEDOMETER
SERVICE
Rear axle gear ratio and tire size determine speed­
ometer pinion requirements. If the gear must be re­
placed, refer to the parts catalogue information for
the correct pinion.

ADAPTER
AND
PINION REMOWAL

(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove speed sensor from speedometer adapter
(Fig. 10). SEAL ADAPTER ADAPTER
RETAINING OIL O-RING
SPEED ADAPTER SPEEDOMETER
SENSOR CLAMP ADAPTER J932M00
Fig. 10 Speedometer Components (4) Check speed sensor mounting area in speedom­
eter adapter. If transmission fluid is found in this area, adapter oil seal is leaking and will have to be
replaced. (5) Remove bolt and retainer securing pinion gear
adapter to extension housing. (6) Carefully work adapter and gear out of hous­
ing. (7) Remove and discard adapter O-ring (Fig. 10).
(8) Remove adapter oil seal if necessary. Start new
seal in adapter by hand. Then press seal into adapter
with Installer Tool C-4004 until tool bottoms (Fig.

10).

ADAPTER AND PINION INSTALLATION AND
ADJUSTMENT

CAUTION:
Before installing
the
pinion
and
adapter

assembly,
make sure
the
adapter flange
and
flange
seat
in the
housing
are
perfectly clean. Dirt
or
for­

eign
material
on
these surfaces
will
cause misalign­ ment resulting
in
pinion gear damage.

(1) Thoroughly clean adapter flange and flange
seat in extension housing.
(2) Lubricate adapter oil seal and O-ring with
transmission fluid.
(3) Count number of teeth on pinion gear before
installing gear in adapter.
(4) Note range numbers on adapter face (Fig. 11).
These numbers correspond to number of teeth on pin­ ion.
(5) Install adapter in extension housing.
(6) Rotate adapter until required range numbers
are at six o-clock position (Fig. 12). Be sure adapter
range numbers correspond to number of teeth on pin­ ion.
(7) Seat adapter in housing.
(8) Install adapter clamp. Tighten clamp bolt to 11
N*m (100 in. lbs.) torque.
(9) Install vehicle speed sensor. Tighten sensor
coupling nut to 17 N*m (150 in. lbs.) torque and in­
stall sensor wires.
(10) Lower vehicle and top off transmission fluid
level.

PARK/NEUTRAL
POSITION SWJTCH
The center terminal of the park/neutral position
switch is the starter circuit terminal. It provides the
ground for the starter solenoid circuit through the se­
lector lever in Park and Neutral positions only. The
outer terminals on the switch are for the backup
lamp circuit.
SWITCH TEST To test the switch, remove the wiring connector.
Then test continuity between the center terminal

•

IN-VEHICLE
SERVICE-32RH/3eRH/37RH/42RH/46RH
21 - 135

SPEEDOMETER
ADAPTER
LOCK
RING

OIL
SEAL
SPECIAL

TOOL

C-4004
J9321-186

Fig. 11 Replacing Speedometer Adapter Seal
RETAINER
-ADAPTER

-7^6
O'CLOCK
POSITION
RH75

Fig.
12 Indexing Speedometer Adapter
and the transmission case. Continuity should exist
only when the transmission is in Park or Neutral.
Shift the transmission into reverse and test conti­
nuity at the switch outer terminals. Continuity should exist only when the transmission is in Re­
verse. Continuity should not exist between the outer
terminals and the case.
Check gearshift linkage adjustment before replac­
ing a switch that tests bad.

SWITCH
REPLACEMENT
(1) Raise vehicle and position drain pan under
switch. (2) Disconnect switch wires.
(3) Remove switch from case.
(4) Move shift lever to Park and Neutral positions.
Verify that switch operating lever fingers are cen­
tered in switch opening in case (Fig. 13).
(5) Install new seal on switch and install switch in

case.
Tighten switch to 34 Nnn (25 ft. lbs.) torque. (6) Test continuity of new switch with 12 volt test

lamp.

(7) Connect switch wires and lower vehicle.
(8) Top off transmission fluid level.
EXTENSION HOUSING
YOKE
SEAL REPLACEMENT (1) Raise vehicle.
(2) Mark propeller and axle yokes for alignment
reference. Then disconnect and remove shaft. (3) Remove old seal with Remover Tool C-3985
(Fig. 14).
SWITCH

RH266

Fig.
13 Park/Neutral Position
Switch
Contacts (4) Start new seal in housing. Then tap seal into
place with Installer Tool
C-3995
or
C-3972
(Fig. 15).
(5)
Carefully guide propeller shaft slip yoke into
housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear
axle pinion yoke.

SPECIAL
TOOL

Fig.
14
Removing
Extension
Housing
Yoke
Seal
SPECIAL
TOOL

RH78

Fig.
15 Installing Extension
Housing
Yoke
Seal

EXTENSION HOUSING BUSHING AND OUTPUT
SHAFT BEARING
SERVlCE-32RH/3eRH/37RH

EXTENSION
HOUSING
REMOVAL
(1) Shift transmission into 1 (manual low) position.
(2) Raise vehicle.
(3) Mark propeller shaft and axle yokes for align­
ment reference. Then disconnect and remove shaft. (4) Remove vehicle speed sensor, speedometer
adapter and speedometer pinion gear (Fig. 10).