1993 DODGE TRUCK Service Repair Manual

21-144
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION

TRANSMISSION
ADAPTER
BOLT AND

;
WASHER
(2)

INSULATOR
SPACER
(2)

UPPER

INSULATOR
(2)

INSULATOR
MOUNTING PLATE

WITH
7"
RAIL
(135
"
WHEELBASE) LOWER
INSULATOR
(2)

J9121-532

Fig.
4
Transmission-To-Crossmember
Attachment (Except 46RH)
(29)
Secure converter in place with small C-clamp
attached to edge of converter housing.

(30)
Lower transmission and remove assembly
from under vehicle.

(31)
Remove C-clamp securing converter in hous­
ing.

(32)
Carefully slide converter out of pump and re­
move it from transmission. Place converter on bench and cover converter hub with tape, cardboard, or pa­
per to prevent dirt entry.

TORQUE CONVERTER
AND
DRIVE PLATE SERVICE
After the transmission has been removed, the drive
plate and torque converter can be replaced or re­
moved for service access.
The torque converter is not a serviceable part. If
the converter is contaminated by a transmission mal­
function, or damaged in any way, it must be replaced as an assembly. Do not attempt to flush a con­
verter contaminated by metal or clutch facing
particles. Flushing will not remove these con­
taminants.
A new torque converter and oil pump are used
in 1993, 42RH transmissions. The new converter
has a different style drive hub. The hub was changed to accept the new design drive flats on
the oil pump inner gear. The drive flats replace
the square lugs used previously. If converter re­ placement should become necessary, be sure to
use the new style converter. The new converter and oil pump are not interchangeable with pre­
vious style parts.

STARTER
RING GEAR
REPLACEMENT

CAUTION:
The
starter
ring
gear
on
standard
torque

converters
can be
replaced when necessary. How­
ever,
the
ring gear
on
torque converters with
a
modulated converter clutch, cannot
be
replaced.
The heat from
welding
will
damage
the
converter
clutch friction material. Converters with
a
clutch
must
be
replaced
as an
assembly
if the
ring gear
is

damaged.

RING GEAR REMOWAL
(1) Cut through weld material at rear side of ring
gear with a hack saw or grinding wheel. Be careful
to avoid cutting or grinding into front cover. (2) Scribe heavy line on front cover next to front
face of ring gear. Line is needed to properly locate new gear on converter. (3) Support torque converter on front cover with
blocks of wood (Fig. 6) Position blocks adjacent to converter lugs to avoid altering lug position. The
torque converter must not rest on the front cover hub during this operation.

•
AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION
21 -
145
ITEM SET-TO-TORQUE
SPECIFICATION

(§)
203
N»m
(150
ft. lbs.)
(D
41
N*m
(30
ft. lbs.)
©
m
N«m
(50
ft. lbs.)

WITH

7"
RAIL
TRANSFER
CASE
Fig.
5
Transmission~To-Cross
(4) Remove ring gear with drift
and
hammer.
Tap

downward
on
gear near welded areas
to
break
any

remaining weld material
(Fig. 6).

(5)
Tap
around ring gear until
it
comes
off
con­
verter.
(6) Smooth weld areas
on
converter with
a
mill
file.
Fig.
6
Removing
Starter
Ring
Gear
mber
Attachment
(With
46RH)
RING GEAR INSTALLATION (1) Heat
and
expand
new
ring gear
for
installation
on converter.
Any of the
following methods
are ac­
ceptable:
(a) OVEN: Place gear
in
oven
and set
tempera­
ture
at
200-250°
F (93° C)
Allow ring gear
to re­

main
in
oven
for 15 to 20
minutes.

(b)
BOILING WATER: Place ring gear
in
shal­
low container.
Add
water
and
heat
for
approxi­
mately eight minutes after water
has
come
to a

boil. (c) STEAM: Place ring gear
on a
flat surface
and

direct steam flow around gear
for
approximately
2
minutes.
(2) After ring gear
is
expanded
by
heating, imme­
diately place gear
in
position
on
converter front cover. (3) Quickly
tap
gear onto cover evenly with plastic
or rawhide mallet. Continue tapping gear until face
of gear
is
even with scribe line (made during
re­

moval)
on the
front cover.
(4) Before proceeding, make sure gear
is
even with
scribed line around full circumference
of the
front cover.
(5)
The
following recommendations
are
provided
as

an
aid to
successfully welding
a new
ring gear
to the
converter.
•
Do NOT
weld with oxy-acetylene equipment

21 - 146
AUTOMATIC
TRANSMISSION REMOVAL
AND
INSTALLATION

• • Use a D.C. welder set at straight polarity, or use
an A.C. welder if the proper electrode is available
• Use 1/8 inch diameter welding rod and a welding
current of 80 to 125 amps. • Direct arc at intersection of gear and front cover at
an angle of 45° from rear face of gear.

(6)
Weld new ring gear to torque converter front
cover. Take care to place same amount of weld mate­
rial (or as nearly as possible) in original weld loca­

tions.
This is essential in maintaining converter
balance. Position welds alternately on opposite sides of converter and ring gear to minimize distortion.
(7) Inspect gear teeth and remove any nicks, raised
metal, weld spatter, or rough surfaces.

PUMP
OIL
SEAL

Seal
Removal
On 32RH/42RH pumps, remove the seal with Spe­
cial Tool C-3981B (Fig. 7).
On 36RH/37RH/46RH pumps, remove the seal with
Special Tool C-3861 (Fig. 8). To use the remover tool, First start the tool into
the seal by hand. Next, thread the tool into the seal as far as it will go. Use a wrench on the tool hex to
turn the tool. Continue tightening until all the tool
threads firmly grip the metal part of the seal. Then
tighten the tool puller screw to withdraw the seal
from the pump body.
Fig. 7 Pump Seal Removal—42RH Fig. 8 Pump Seal Removal—46RH
Seal
Installation

On 32RH/42RH pumps, use Installer Tool C-4193
to install the new seal (Fig. 9).
On 36RH/37RH/46RH pumps, use Installer Tool
C-3860-A (Fig. 9).
To use the tool, place the seal in the pump opening
with the seal lip facing inward. Then tap the seal into place with the installer tool (Fig. 9). Tool Han­
dle C-4171 may be used with the installer tool if de­ sired.
J932M80
Fig. 9 Pump Seal Installation

TRANSMISSION
AND TORQUE CONVERTER INSTALLATION—2-WHEEL DRIVE

(1) Mount transmission on jack. Secure transmis­
sion with safety chains. (2) Check converter hub and hub drive notches for
sharp edges, burrs, scratches, or nicks. Polish hub
and notches with 400 grit wet/dry paper or crocus
cloth if necessary. Hub surface must be smooth to avoid damaging pump seal at installation. (3) Lubricate converter drive hub and pump seal
lip with transmission fluid. (4) Install converter in oil pump.
(5) Verify that converter is fully seated. Use
straight edge and steel ruler to check seating (Fig.
10).
Surface of converter lugs should be approxi­
mately 13 mm (1/2 in.) to rear of straight edge when
converter is fully seated. (6) Temporarily secure converter with C-clamp at­
tached to housing or with metal strap attached across converter housing. (7) Mount transmission on jack and secure it with
safety chains. (8) Check condition of converter driveplate. Re­
place plate if cracked, distorted or damaged. If driveplate replacement was necessary, be sure
transmission dowel pins are seated in engine
block and protrude far enough to held transmis­ sion in alignment. (9) Raise transmission and align converter with
crankshaft and drive plate.

•

AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION
21 - 147

Fig.
10 Checking Torque Converter Seating (10) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
dowels in engine block.
(11) Rotate converter until alignment mark scribed
on converter is aligned with mark on driveplate.
Off­
set holes in plate are next to 1/8 in. hole in inner cir­
cle of plate (Fig. 1).
(12) Carefully work transmission forward until
converter hub is seated.
(13) Install bolts attaching converter housing to
engine block. (14) Install crossmember and brackets.
(15) Lower transmission onto crossmember and in­
sulator. Then install bolts attaching transmission
mount to crossmember.
(16) Remove fixture used to support engine.
(17) Connect wires to vehicle speed sensor.
(18) Install new plastic retainer grommet on any
shift linkage rod or lever that was disconnected. Old
grommets should not be reused. Use pry tool to re­
move rod from grommet and cut away old grommet.
Use pliers to snap new grommet into lever and to
snap rod into grommet.
(19) Connect gearshift linkage and transmission
throttle cable to levers on manual valve shaft.
(20) Connect wires to park/neutral position switch,
transmission solenoid(s) and oxygen sensor. Be sure
transmission harnesses are properly routed (Figs. 11 and 12).

CAUTION:
It is
essential
that
correct length bolts
be
used
to
attach
the
converter
to the
driveplate. Bolts

that
are too
long
will
damage
the
clutch surface
in the
converter.
If new
bolts
are
required,
use the
bolts
specified
in
this procedure
and in the
parts
book only.
SENSOR

NEUTRAL
START
AND

BACKUP
LAMP
SWITCH

J9021-76

Fig.
11
Transmission
Wire
Routing—32RH/36RH
ENGINE

J9021-75
Fig.
12
Transmission
Wire
Routing—42RH/46RH

(21) Verify converter bolt length. Bolt measure­
ment is from bottom (underside) of bolt head to end of bolt threads.
• On 9.5 in., 3-lug converter, bolts should be 0.46 in. (11.7 mm) long.

21 - 148
AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION

•

ITEM
TORQUE

A
27-54
N-m
(20-40
ft. lbs.)

B
9-14
N-m
(80-120
in.
lbs.)

C
3-6 N-m
(30-50
in. lbs.)

D
47-88
N-m
(35-65
ft. lbs.)

E
14-20 N-m
(125-175
in. lbs.)
PLATE

FILL

TUBE

BRACKET
TRANSMISSION

DIPSTICK

DAMPER

WEIGHT

STRUT
DUST

COVER
J9321-232

Fig. 13 Transmission And Fill Tube Attachment
3-lug converter, tighten
4-lug converter, tighten • On 9.5 in., 4-lug converter, bolts should be 0.52 in.
(13.2 mm) long.
• On 10.75 in., 4-lug converter, bolts should be 0.44
in. (11.2 mm) long. (22) Install torque converter attaching bolts.
Tighten bolts as follows:
• On models with 9.5 in.,
bolts to 54 Nnn (40 ft. lbs.) • On models with 9.5 in.,
bolts to 74 Nnn (55 ft. lbs.) • On models with 10.75 in., 4-lug converter, tighten
bolts to 31 Nnn (270 in. lbs.)
• On diesel models, tighten converter bolts to 47
Nnn (35 ft. lbs.) torque (23) Install converter housing dust cover. (24) Install starter motor and cooler line bracket.
(25) Connect cooler lines to transmission.
(26) Install transmission fill tube (Fig. 13). Install
new O-ring seal on tube before installation. (27) Install any exhaust components that were re­
moved, or moved for service access. (28) Align and install propeller shaft. Tighten
shaft U-joint clamp bolts to 19 Nnn (170 in. lbs.)
torque. (29) Lower vehicle.
(30) Fill transmission with Mopar ATF Plus, Type

7176,
or Mopar Dexron II if ATF Plus is not readily
available. (31) Check and adjust gearshift and throttle valve
linkage if necessary.

TRANSMISSION
AND
TORQUE CONVERTER INSTALLATION—4-WHEEL DRIVE

CAUTION:
The
transmission cooler
and
lines must be flushed
if
repair
corrected
a
problem that gener­
ated
sludge,
metal particles,
or
clutch friction mate­ rial.
The
torque
converter
should
also
be replaced

when contaminated
by a
malfunction.
The
transmis­
sion,
fluid
and
converter
will
be
contaminated again if residue/debris
is not
flushed from
the
cooler
and

lines
beforehand.

(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish hub and notches with 400 grit paper or crocus
cloth if necessary. Hub must be smooth to avoid dam­ aging pump seal during installation.
(2) Lubricate converter hub and pump seal lip with
transmission fluid.
(3) Position converter hub so drive slots will be
aligned with pump gears. Then carefully insert con­
verter hub into pump and gears.
(4) Verify that converter is fully seated. Use
straight edge and steel ruler to check seating (Fig.

•

AUTOMATIC
TRANSMISSION
REMOVAL
AND
INSTALLATION
21 - 149
10).
Surface of converter lugs should be approxi­
mately 13 mm (1/2 in.) to rear of straight edge when converter is fully seated.
(5) Temporarily secure converter in pump and
housing with C-clamp attached to housing edge, or
with metal strap attached across converter housing.
(6) Position transmission on jack. Secure transmis­
sion to jack with safety chains.
(7) Check condition of converter driveplate. Re­
place plate if cracked, distorted or damaged. If driveplate replacement was necessary, be sure
transmission dowel pins are seated in engine block and protrude far enough to held transmis­ sion in alignment.
(8) Coat pilot hub of torque converter with trans­
mission fluid.
(9) Raise transmission and align converter with
drive plate and crankshaft.
(10) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
dowels on engine block.
(11) Rotate converter to align marks scribed on
converter and driveplate. Offset holes in plate are
next to 1/8 in. hole in inner circle of plate (Fig. 1).
(12) Carefully work transmission forward and over
engine block dowels until converter hub is seated in crankshaft.
(13) Install bolts attaching converter housing to
engine.
(14) Install crossmember.
(15) Lower transmission onto crossmember and in­
stall bolts attaching transmission and insulator to
crossmember (Figs. 4 and 5). (16) Remove fixture used to support engine.
(17) Connect vehicle speed sensor wires. (18) Install new plastic retainer grommet on any
shift linkage rod or lever that was disconnected. Old
grommets should not be reused. Use pry tool to re­
move rod from grommet and cut away old grommet.
Use pliers to snap new grommet into lever and to snap rod into grommet. (19) Connect gearshift and throttle linkage to
transmission. (20) Connect wires to park/neutral position switch,
transmission solenoids and to oxygen sensor. Be sure
transmission harnesses are properly routed.

CAUTION:
It is essential
that
correct length
bolts
be

used
to
attach
the
converter
to the
driveplate.
Bolts

that
are too long
will
damage
the
clutch
surface
in
the converter. If new
bolts
are required, use the
bolts
specified in this procedure and in the parts
book
only.

(21) Verify converter bolt length. Bolt measure­
ment is from bottom (underside) of bolt head to end
of bolt threads. • On 9.5 in., 3-lug converter, bolts should be 11.7
mm (0.46 in.) long.
• On 9.5 in., 4-lug converter, bolts should be 13.2
mm (0.52 in.) long.
• On 10.0 in., 4-lug converter, bolts should be 13.2
mm (0.52 in.) long.
• On 10.75 in., 4-lug converter, bolts should be 11.2
mm (0.44 in.) long.
(22) Install torque converter bolts. Tighten bolts as
follows:
• On models with 9.5 in., 3-lug converter, tighten
bolts to 54 Nnn (40 ft. lbs.).
• On models with 9.5 in., 4-lug converter, tighten
bolts to 74 Nnn (55 ft. lbs.).
• On models with 10.0 in., 4-lug converter, tighten
bolts to 74 Nnn (55 ft. lbs.) torque.
• On models with 10.75 in., 4-lug converter, tighten
bolts to 31 Nnn (270 in. lbs.).
• On diesel models with 12.2 in. converter, tighten
bolts to 47 Nnn (35 ft. lbs.) torque.
(23) Install converter housing access cover. (24) Install starter motor and cooler line bracket.
(25) Connect cooler lines to transmission.
(26) Install transmission fill tube. Install new
O-ring seal on tube before installation.
(27) Install any exhaust components removed for
service access. (28) Support transfer case on transmission jack.
Secure transfer case to jack with safety chains. (29) Install gasket on transmission adapter. Coat
gasket with Mopar perfect, seal, or silicone sealer be­
forehand. (30) Install transfer case on transmission. Tighten
transfer case attaching nuts to 47 Nnn (35 ft. lbs.) torque. (31) Remove jack supporting transfer case.
(32) Connect transfer case shift lever to range le­
ver. (33) Align and install propeller shafts. Tighten
clamp bolts to 19 Nnn 170 in. lbs.) torque. (34) Install transfer case skid plate and crossmem­
ber. (35) Lower vehicle.
(36) Fill transmission with Mopar ATF Plus, Type
7176, or Mopar Dexron II if ATF Plus is not readily
available. (37) Check and adjust gearshift, throttle valve and
transfer case shift linkages if necessary.

OVERDRIVE
UNIT
REMOVAL—42RH/46RH
The following removal and installation procedures
apply to the 42RH/46RH overdrive unit only. If the
complete transmission assembly must be removed,
refer to the Transmission And Converter Removal and Installation procedures. (1) Shift transmission into Park.
(2) Raise vehicle.

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.