1993 DODGE TRUCK Service Repair Manual

21-168
TRANSMISSION
OVERHAUL—32RH

REAR

CLUTCH PISTON CLUTCH
PISTON

SEALS
OUTPUT
SHAFT
THRUST

WASHER
(METAL) INPUT
SHAFT

SNAP
RING
REAR

CLUTCH
RETAINER INPUT
SHAFT
-REAR

CLUTCH

.
THRUST

" /
SHAFT WASHER
/
FRONT
('I"")

SHAFT SEAL
REAR
RING
rniTru
SEAL
(TEFLON)
C^TCH
RING PACK
SNAP
RING
(SELECTIVE)
PISTON

SPRING

BOTTOM

PRESSURE
PLATE CLUTCH

DISCS
(4)
TOP

PRESSURE
PLATE

J9121-539

Fig.
62 Rear
Clutcl
REAR
CLUTCH OVERHAUL

REAR
CLUTCH DISASSEMBLY
(1) Remove fiber thrust washer from forward side
of clutch retainer. (2) Remove selective clutch pack snap ring (Fig.

62).

(3) Remove top pressure plate, clutch discs, steel

plates,
bottom pressure plate and wave spring (Fig.
62).
(4) Remove clutch piston with rotating motion.
(5) Remove and discard piston seals.
(6) Remove input shaft snap ring (Fig. 63). (7) Press input shaft out of retainer with shop
press and suitable size press tool (Fig. 64).
(8) Remove input shaft front/rear seal rings.

REAR
CLUTCH INSPECTION
Clean the clutch components with solvent and dry
them with compressed air. Do not use rags or shop
towels to dry any of the clutch parts. Lint from such materials will adhere to component surfaces and
could restrict or block fluid passages after assembly.
Replace the clutch discs if warped, worn, scored,
burned/charred, the lugs are damaged, or if the fac­ ing is flaking off. Replace the top and bottom pres­sure plates if scored, warped, or cracked. Be sure the
driving lugs on the pressure and clutch plates are
Components—32
RH
Fig.
63 Removing/Installing Input Shaft
Snap
Ring-32RH
also in good condition. The lugs must not be bent,
cracked or damaged in any way. Replace the piston spring and wave spring if either
part is distorted, warped or broken. Check the lug grooves in the clutch retainer. The
clutch and pressure plates should slide freely in the
slots.
Replace the retainer if the grooves are worn or

•

TRANSMISSION
OVERHAUL—32RH
21 - 111

J9121-150

Fig. 64 Pressing input Shaft Out Of Rear Clutch Retainer—32RH damaged. Also check action of the check balls in the
retainer and piston. Each check ball must move
freely and not stick.
Replace the retainer bushing if worn, scored, or
doubt exists about bushing condition.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.
Check condition of the fiber thrust washer and
metal output shaft thrust washer. Replace either
washer if worn or damaged.
Check condition of the seal rings on the input shaft
and clutch retainer hub. Replace the seal rings only
if worn, distorted, or damaged. The input shaft front seal ring is teflon with chamfered ends. The rear
ring is metal with interlocking ends.
Check the input shaft for wear, or damage. Replace
the shaft if worn, scored or damaged in any way.

ASSEMBLING REAR
CLUTCH

(1) Soak clutch discs and steel plates in transmis­
sion fluid.

(2)
Install new seal rings on clutch retainer hub
and input shaft (Fig. 65).
(a) Be sure clutch hub seal ring is fully seated in
groove and is not twisted.
(b) Note that input shaft front seal ring is teflon
and rear seal ring is metal (Fig. 66). Be sure cham­
fered ends of teflon ring are properly joined and
that ends of rear ring are securely hooked together. Lubricate both rings with light coat of petroleum
jelly after installation.
(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then press input shaft into retainer (Fig. 67).

(4)
Install input shaft snap ring (Fig. 63).
(5) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
J9121
-538

Fig.
65 Rear Clutch Retainer And input Shaft
Seal Ring
Installation—32RH
J912M51 Fig. 66 input Shaft Seal
Ring
Identification—32RH
(6) Lubricate lip of piston seals with liberal quan­
tity of Door Eze, or petroleum jelly. Then lubricate
retainer hub and bore with transmission fluid. (7) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. Do not attempt to push the piston straight in. This
could fold the seals over causing leakage and
clutch slip.

21
- 170
TRANSMISSION OVERHAUL—32RH

•

Fig.
67
Pressing
input Shaft
into
Rear
Clutch
Retainer—32RH (8) Install piston spring in retainer and on top of
piston (Fig. 68). Concave side of spring faces down­ ward (toward piston).
(9) Install wave spring in retainer (Fig. 68). Be
sure spring is completely seated in retainer groove.
Fig.
68
Piston
And Wave
Spring
Position—32RH
(10) Install bottom pressure plate (Fig. 62). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.
(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 in­stalled. Total of 4 discs and 3 plates are required (Fig. 62). (12) Install top pressure plate (Fig. 62). (13) Install selective snap ring (Fig. 62). Be sure
snap ring is fully seated in retainer groove. (14) Measure clutch pack clearance (Fig. 69).
Clearance should be 0.64 - 1.14 mm (0.025 - 0.045

in.).
If clearance is incorrect, steel plates, discs, snap
ring and pressure plates may have to be changed.
Fig.
69 Typical Method Of
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. 70). Use enough petroleum
jelly to hold washer in place.
(16) Set rear clutch aside for installation during fi­
nal assembly.
Fig.
70 Installing Rear
Clutch
Thrust Washer—32RH

TRANSMISSION
OVERHAUL—32RH
21 - 171

PLANETARY GEAR TRAIN
OVERHAUL

•OUTPUT
SHAFT

PLANETERY GEARTRAIN DISASSEMBLY (FIG.
71) (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.
(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 output shaft. (10) Remove snap rings that secure annulus gears
to supports and separate each gear from the 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 of these parts
that are worn, distorted or damaged. Do not attempt
to reuse these parts.
Inspect the output shaft carefully. Pay particular
attention to the machined bushing/bearing surfaces
on the shaft and the governor valve shaft bore at the
shaft rear.
Replace the output shaft if the machined surfaces
are scored, pitted, or damaged in any way. Also re­
place the shaft if the splines are damaged, or exhib­ its cracks at any location (especially at the governor
valve shaft bore).
ASSEMBLING PLANETARY GEARTRAIN
(1)
Lubricate output shaft and planetary compo­
nents with transmission fluid. Use petroleum jelly to
lubricate and hold thrust washers and plates in posi­
tion.
(2) Assemble rear annulus gear and support if dis­
assembled. Be sure support snap ring is seated and

SELECT
FIT

PLANETARY
SNAP
RING FRONT
ANNULUS
SNAP
RING SUPPORT ANNULUS GEAR

SNAP
RING SUPPORT FRONT
PLANETARY THRUST

WASHERS
SUN

GEAR
SUN

GEAR

SPACER
DRIVING SHELL FRONT DRIVING
THRUST PLATE SHELL
FRONT
ANNULUS. THRUST

WASHER

DRIVING
SHELL
REAR

THRUST PLATE
OUTPUT

SHAFT
THRUST PLATE
OUTPUT

SHAFT
J9221-17

Fig.
71 Planetary Gear Train—32RH

21
- 172
TRANSMISSION OVERHAUL—32RH

• that shoulder-side of support faces rearward (Fig.

72).
(3) Install rear thrust washer on rear planetary
gear (Fig. 72). 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. 72).
Fig. 72
Assembling
Rear
Annulus
And Planetary
Gear-32RH

(5) Install assembled rear planetary and annulus
gear on output shaft (Fig. 73). Verify that assembly
is fully seated on shaft.

Fig.
73 installing Assembled Rear Annulus And Planetary Gear On Output Shaft-32RH
(6) Install front thrust washer on rear planetary
gear (Fig. 74). Use enough petroleum jelly to hold
washer on gear.
(7) Install spacer on sun gear (Fig. 75). (8) Install thrust plate on sun gear (Fig. 76). Note
that driving shell thrust plates are interchangeable. Use either plate on sun gear and at front/rear of shell. Fig. 74 installing Rear Planetary Front Thrust

Washer-32RH

Fig. 75 Installing Spacer On Sun Gear—32RH
Fig. 76 Installing Driving Shell Front Thrust Plate On Sun Gear-32RH

•

TRANSMISSION
OVERHAUL—32RH
21 - 173 (9) Hold sun gear in place and install thrust plate
over sun gear at rear of driving shell (Fig. 77).
DRIVING
SHELL SUN
GEAR
REAR

THRUST
PLATE
J912M62

Fig.
77 Installing Driving
Shell
Rear Thrust Piate-32RH
(10) Position wood block on bench and support sun
gear on block (Fig. 78). This makes it easier to align
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.
78
Supporting
Sun Gear On
Wood
Block—32RH

(11) 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. 79).
(12) Install assembled driving shell and sun gear
on output shaft (Fig. 80).
(13) Install rear thrust washer on front planetary
gear (Fig. 81). Use enough petroleum jelly to hold
washer on gear and be sure washer tabs are all prop­ erly seated.
(14) Install front planetary gear on output shaft
and in driving shell (Fig. 82).
LOCK
RING
GROOVE SUN
GEAR LOCK RING
REAR

THRUST
PLATE
DRIVING SHELL
Fig.
79 Installing Sun Gear
Lock
Ring—32RH
SUN GEAR/
DRIVING SHELL
ASSEMBLY

OUTPUT
SHAFT
J912M65

Fig.
80 Installing
Assembled
Sun Gear And Driving
Shell
On Output Shaft-32RH

REAR
TABBED

THRUST

WASHER
FRONT

PLANETARY GEAR

J912M66

Fig.
81 Installing Rear Thrust
Washer
On Front Planetary Gear—32RH

21
- 174
TRANSMISSION
OVERHAUL—32RH

• (15) Install front thrust washer on front planetary
gear (Fig. 82). Use enough petroleum jelly to hold
washer in place on gear and be sure washer tabs are seated.
(16) Assemble front annulus gear and support. Be
sure support snap ring is seated. (17) Position thrust plate on front annulus gear
support (Fig. 83). Use enough petroleum jelly to hold
thrust plate in place. (18) Install front annulus assembly on front plane­
tary gear (Fig. 82).

Fig.
82 Installing Front Planetary And
Annulus
Gears—32RH

Fig.
83
Positioning
Thrust
Plate
On
Annulus
Support—32RH

(19) Install front annulus thrust washer (Fig. 84).
Align flat on washer with flat on planetary hub. Also
be sure washer tab is facing forward.
(20) Install front annulus snap ring (Fig. 85). Use
snap ring pliers to avoid distorting ring during in­
stallation. Also be sure ring is fully seated. (21) Install planetary selective snap ring with snap
ring pliers (Fig. 86). Be sure ring is fully seated.
(22) Turn planetary geartain assembly over so
Fig.
84 installing Front
Annulus
Thrust

Washer-32RH
Fig.
85 Installing Front
Annulus Snap
Ring—32RH

SELECTIVE

Fig.
86 Installing Planetary Selective
Snap
Ring—32
RH

driving shell is facing workbench. Then support geartrain on wood block positioned under forward

•

TRANSMISSION
OVERHAUL—32RH
21 - 175 end of output shaft. This allow geartrain components
to move forward for accurate end play check. (23) Check planetary geartrain end play with
feeler gauge (Fig. 87). Gauge goes between shoulder on output shaft and end of rear annulus support.
(24) 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.
87
Checking
Planetary
Geartrain
End
Play-32RH

FRONT
SERVO
AND BAND OVERHAUL

FRONT
SERWO DISASSEMBLY
(FIG. 88) (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.

FRONT
SERWO
AND
BAND
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.
SERVO

PISTON

SNAP GUIDE RING
SEAL J912M72

Fig.
88 Front
Servo
Components—32RH
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. 88).

REAR
SERVO
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. 89). 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.

89).

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

REAR SERVO
INSPECTION
Clean the servo components 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 reaction pins. Replace the O-rings
on both pins. Minor pin scoring can be cleaned up
with crocus cloth. However, replace the pins if worn, severely scored, or cracked.
Inspect the servo components (Fig. 90). Replace the