1993 DODGE TRUCK Service Repair Manual

21 - 136
IN-VEHICLE
SERVICE—32RH/36RH/37RH/42RH/46RH

•
(5)
Remove bolts attaching extension housing to
rear support.
(6) Raise transmission slightly with jack stand or
floor jack. (7) Remove crossmember and rear support as as­
sembly.
(8) Remove extension housing attaching bolts.
(9) Remove access plate and gasket from underside
of extension housing. Plate must be removed for ac­
cess to rear bearing locating ring.
(10) Insert parallel jaw snap ring pliers into access
plate opening and spread bearing locating ring (Fig.
16).
(11) Hold snap ring in a spread position and work
extension housing off rear bearing.

Fig.
16
Releasing
Rear Bearing Locating
Ring

(12) Carefully pull extension housing rearward to
move park lock rod past sprag and remove housing.

OUTPUT
SHAFT
REAR
BEARING

REPLACEMENT

(1) Remove snap ring that retains rear bearing on
output shaft (Fig. 17).

Fig.
17 Rear Bearing Location
(2) Remove bearing from output shaft. Note that
36RH/37RH transmissions have a second snap ring
at front of shaft bearing. 32RH transmissions do not
have this second snap ring. (3) Install new bearing on shaft. Be sure locating
ring groove in outer circumference of bearing is to­
ward front (Fig. 17). (4) Install rear bearing retaining snap ring (Fig.

16).
However, do not install the locating ring on the
bearing. The locating ring goes in the extension
housing. The ring is not seated in the rear bearing until the housing is installed.

EXTENSION
HOUSING
BUSHING

REPLACEMENT
(1) Remove housing oil seal with Remover Tool
C-3985 (Fig. 18).

Fig.
18
Removing
Extension
Housing
Seal

(2) On 32RH, remove housing bushing with bush­
ing Tool C-4470. On 36RH/37RH, remove bushing
with Tool C-4469 (Fig. 19).
(3) On 32RH, slide new bushing on installing end
of Tool C-4470. On 36RH/37RH, slide bushing on
Tool C-4469 (Fig. 19).
(4) Align bushing oil hole with oil slot in extension
housing. Then tap bushing into place (Fig. 19).
(5) Install new seal in housing (Fig. 20). On 32RH
use Seal Installer C-3995. On 36RH/37RH, use Seal
Installer C-3972.

Fig.
19 Extension
Housing
Bushing
Replacement

EXTENSION
HOUSING
INSTALLATION
(1) Position new gasket on housing. Use petroleum
jelly to hold gasket in place.
(2) Install locating ring in extension housing, if re­
moved.
(3) Slide housing onto output shaft.

IN-VEHICLE
SERVICE-32RH/38RH/37RH/42RH/46RH
21 - 137

SPECIAL TOOL GOVERNOR SUPPORT

AND
PARKING GEAR RH78

Fig. 20 installing Extension Housing
Seal

(4) Work park rod past sprag and move housing
into place on shaft.
(5) Spread rear bearing locating ring with parallel
jaw snap ring pliers. (6) Hold locating ring in spread position. Then
push housing forward until locating ring seats in
bearing and housing seats against transmission case. Be sure locating ring is fully seated in rear bearing.
(7) Install and tighten housing attaching bolts to
43 Nnn (32 ft. lbs.) torque.
(8) Install gasket and access plate on underside of
housing.
(9) Install crossmember and rear mount assembly.
(10) Remove jack used to support transmission.
(11) Install and tighten housing-to-rear mount
bolts to 68 Nnn (50 ft. lbs.) torque. (12) Install speedometer pinion and adapter.
(13) Align and install propeller shaft. (14) Lower vehicle.
(15) Top off transmission fluid level if necessary.

GOVERNOR AND PARK GEAR SERVICE—32RH/

3SRH/37RH

GOVERNOR
AND
PARK
GEAR
REMOVAL
(1) Remove extension housing and output shaft
rear bearing. Refer to procedure in this section.
(2) Carefully remove snap ring from weight end of
governor valve shaft (Fig. 21). (3) Slide governor valve and shaft out of governor
body. (4) Remove large snap ring from weight end of gover­
nor body and remove governor weight assembly.
(5) Remove snap ring from governor weight and
remove inner weight and spring from outer weight (Fig. 21).
(6) Remove snap ring retaining governor body and
park gear on output shaft (Fig. 22). (7) Slide governor body and park gear assembly off
output shaft. (8) Remove bolts attaching governor body to gear
and separate body from gear. (9) Remove filter screen from governor body.

GOVERNOR/PARK
GEAR
CLEANING
AND

INSPECTION

Thoroughly clean all the governor parts in a suit­
able cleaning solution but do not use any type of
caustic cleaning agents.
GOVERNOR BODY
LOCKING BOLTS
(4)

Fig.
21
Governor
Snap
Ring
Locations-
37RH
RH269
-32RH/36RH/
The weights and valves should fall freely in their
bores when clean and dry.
Minor surface scratches and burrs can be removed
with crocus cloth. Inspect the governor weight spring for distortion. Replace the spring, if damaged. Clean the filter in solvent and dry it with com­
pressed air. Replace the filter if damaged. Inspect the park gear for chipped or worn gear
teeth or damaged ring grooves. Replace the gear, if damaged.
SPRING
OUTER WEIGHT
SNAP
RINGS
INNER WEIGHT VALVET SHAFT
VALVE
SNAP
RING

FILTER SCREEN

J9221-51

Fig.
22
Governor
Components—32RH/36RH/37RH
GOVERNOR/PARK
GEAR
ASSEMBLY
AND

INSTALLATION
(1) Assemble governor body, filter screen and park
gear.

21
- 138
IN-VEHICLE SERVSCE-32RH/36RH/37RH/42RH/46RH

(2) Install and tighten gear-to-body bolts finger
tight. Make sure oil passage in governor body aligns
with matching passage in gear. (3) Install assembled governor body and gear on
output shaft.
(4) Position governor body so valve shaft hole in
body aligns with matching hole in output shaft. Then slide body and park gear into place. (5) Install snap ring securing governor and park
gear to output shaft (Fig. 22).
(6) Tighten bolts attaching governor body to park
gear to 11 N»m (95 in. lbs.) torque.
(7) Assemble governor weights and spring. Secure
inner weight and spring in outer weight with snap
ring (Fig. 21).
(8) Install weight assembly in governor body and
install retaining snap ring (Fig. 21).
(9) Place governor valve on valve shaft. Insert shaft
in governor body, through governor weights and output
shaft. Be sure valve is properly seated in body.
(10) Secure valve shaft with small snap ring.
(11) Install output shaft bearing and extension
housing. Refer to procedure in this section.

GOVERNOR
AND
PARK LOCK SERVICE—42RH/
46RH

The governor and park lock components are located
within the overdrive unit and cannot be serviced in
the vehicle. The overdrive unit must be removed and disassem­
bled for access to the governor and park lock compo­
nents.
Refer to the 42RH/46RH overdrive unit service sec­
tions for repair procedures.

PARK
LOCK SERVICE—32RH/36RH/37RH
PARK LOCK
COMPONENT REMOVAL
(1) Remove extension housing as described in this
section. (2) Slide sprag shaft out of extension housing and
remove sprag and spring (Fig. 23).
(3) Remove snap ring and slide reaction plug and
pin assembly out of housing. (4) If park rod requires service, it will be necessary
to remove valve body. Refer to Valve Body Service
procedures in this section.

COMPONENT INSPECTION
Inspect the sprag shaft for scores and free move­
ment in the housing and sprag. Inspect the sprag and control rod springs for distortion and loss of tension.
Inspect the square lug on the sprag for broken

edges.
Check the lugs on the park gear for damage. Inspect the ball on the end of the control rod for
nicks and burrs. Also be sure the ball rotates freely.
J9221-249

Fig. 23
Park
Lock Components-32RH/36RH/37RH
PARK
LOCK
COMPONENT INSTALLATION

(1) Install reaction plug and pin assembly in hous­
ing and secure with new snap ring (Fig. 23).
(2) Position sprag and spring in housing and insert
sprag shaft. Be sure square lug on sprag is toward
park gear. Also be sure spring is positioned so it moves sprag away from gear.
(3) Replace park rod if necessary. (4) Install extension housing as described in this
section.

VALVE BODY
SERVICE

GENERAL SERVICE
INFORMATION
The valve body can be removed for service without
having to remove the entire transmission assembly. The valve body can be disassembled for cleaning
and inspection of the individual components. Refer to
the procedures in the Transmission Unit Subassem­
bly Overhaul section.
The only serviceable valve body components are

the:

• manual lever
• manual lever washer/seal/E-clip and shaft seal
• manual lever detent ball
• throttle lever
• fluid filter
• overdrive solenoid and connector assembly
• switch valve, spring and adjusting screw bracket • converter clutch solenoid The remaining valve body components are serviced
only as part of a complete valve body assembly.

VALVE
BODY
REMOVAL
(1) Raise vehicle.
(2) Remove oil pan and drain fluid.
(3) Loosen clamp bolts and remove throttle and
manual valve levers from manual lever shaft. (4) Remove park/neutral position switch. (5) Remove filter from valve body.
(6) Disconnect converter clutch solenoid wire from
case connector.

•

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

21 - 139 (7) Push solenoid connector out of case.
(8) Remove valve body attaching screws.
(9) Lower valve body enough to remove accumula­
tor piston and piston spring (Fig. 24).
(10) Pull valve body forward to disengage park rod. (11) Push manual lever shaft and solenoid case
connector out of transmission case. Lower valve body,
rotate it away from case, pull park rod out of sprag and remove valve body (Figs. 25 and 26).
ACCUMULATOR
OUTER

PISTON
SPRING

INNER
SEAL

SPRING
RINGS
J932M87

Fig.
24
Accumulator
Piston
And
Springs
(42RH/
46RH
Shown)

Fig.
25
Valve
Body
Assembly—4-Speed
Transmission
VALVE
BODY
INSTALLATION

(1) Verify that park/neutral position switch has
NOT been installed. Valve body cannot be installed
with switch in place. Remove switch if necessary.
(2) Install new seals on accumulator piston and in­
stall piston in case.
(3) Place valve body manual lever in low (1 posi­
tion) to ease installing park rod in sprag.
(4) Use screwdriver to push park sprag into en­
gagement with park gear. This allows knob on rod to
MANUAL
CONVERTER

LEVER
CLUTCH
- Fig. 26
Valve
Body
Assembly—3-Speed

Transmission

move past sprag when valve body is installed. Rotate
output shaft to verify sprag engagement. (5) Position accumulator spring between accumula­
tor piston and valve body.
(6) Position valve body on transmission and work
park rod past sprag. Be sure accumulator piston and spring remain in position.
(7) Hold valve body in position and install valve
body attaching screws linger tight only.
(8) Install park/neutral position switch in case.
(9) Tighten valve body attaching screws alter­
nately and evenly to 11 N#m (100 in. lbs.) torque.
(10) Install new fluid filter on valve body. Install
and tighten filter screws to 4 N-m (35 in. lbs.) torque. (11) Connect solenoid wire to case connector.
(12) Install manual and throttle levers on throttle
lever shaft. Tighten lever clamp screws and check for
free operation. Shaft and levers must operate freely
without any bind.
(13) Install oil pan and new gasket. (Tighten pan
bolts to 17 N»m (150 in. lbs.) torque. (14) Connect park/neutral position switch and con­
verter clutch solenoid wires.
(15) Install speedometer pinion gear, adapter and
speed sensor.
(16) Lower vehicle.
(17) Fill transmission with Mopar ATF Plus, Type

7176,
or Dexron II™ fluid if ATF Plus is not readily
available. (18) Adjust gearshift and throttle linkage.

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.