1993 DODGE TRUCK Service Repair Manual

21
- 176
TRANSMISSION
OVERHAUL—32RH

•

SMALL

WOOD

BLOCK

PISTON PLUG

SNAP
RING
SNAP

RING

PLIERS

J912M74

Fig.
89 Removing/installing
Servo
Piston
Plug Snap
Ring-32
RH
servo and cushion springs if collapsed, distorted or
broken. Replace the plug or piston if cracked, bent, or worn. Discard the servo snap ring and spring re­
tainer if distorted or warped.
If doubt exists about the condition of any servo
component, replace it. Do not reuse suspect parts.

SPRING

RETAINER

SERVO

SPRING

PISTON PLUG
CUSHION
SPRING
SERVO

SNAP
RING
PISTON
SEAL
PISTON
PLUG

SNAP
RING
SERVO

PISTON
J9121-173

Fig.
90 Rear
Servo
Components—32RH

ASSEMBLING
REAR SERVO PISTON
(1) Assemble piston plug, cushion spring and pis­
ton (Fig. 90). (2) Compress cushion spring in vise and install pis­
ton plug snap ring (Fig. 90).
(3) Install new seal on piston. Be sure seal lip is
toward servo bore (Fig. 91).
(4) Lubricate piston seal with petroleum jelly. Lu­
bricate other servo parts with transmission fluid.
BE
SURE

SEAL
LIP

IS
TOWARD

SERVO
BORE

REAR

SERVO

PISTON

J9121-175
Fig.
91 Installing Rear
Servo
Piston
Seal—32RH

VALVE
BODY
SERVICE
AND ADJUSTMENT
VALVE BODY DISASSEMBLY

CAUTION:
Do not
clamp
any
part
of the
valve body

assembly
(Fig.
92) in a
vise.
This practice
will
dis­

tort
the
valve body
and
transfer plate resulting
in

valve bind. Slide valves
and
plugs
out
carefully.
Do
not
use
force
at any
time.
The
valves
and
valve

body
will
be
damaged
if
force
is
used.
Also
tag or

mark
the
valve body
springs
for
reference
as
they
are removed.
Do not
allow them
to
become
inter­
mixed.

MANUAL
LEVER
CONVERTER
CLUTCH
MODULE
AND TUBE MANUAL
VALVE
SOLENOID WIRE
PARK

ROD
CONVERTER
CLUTCH
SOLENOID

J9321-125

Fig.
92 Valve
Body
Assembly—32RH

(1) Remove screws attaching adjusting screw
bracket to valve body and transfer plate. Hold
bracket firmly against spring force while removing last screw.
(2) Remove adjusting screw bracket, line pressure
adjusting screw, pressure regulator spring and switch
valve spring (Fig. 93). Do not remove throttle

•

TRANSMISSION
OVERHAUL—32RH
21 - 177 pressure adjusting screw from bracket and do
not disturb adjusting screw settings during re­
moval.

SPRING
J912M76

Fig.
93 Adjusting
Screw
Bracket And
Spring
Removal—32RH
(3) Secure detent ball and spring in housing with
Retainer Tool 6583 (Fig. 94).
DETENT BALL
AND
SPRING
HOUSING
J9321-121

Fig.
94
Securing
Detent
Ball
And
Spring
With
Retainer Tool (4) Remove manual shaft E-clip and washer (Fig.

95).
(5) Pull manual shaft and park rod assembly up­
ward out of valve body and off throttle lever (Fig.
95).
(6) Remove retainer tool and remove detent ball
and spring (Fig. 95).
(7) Remove throttle lever (Fig. 95).
(8) Remove park rod E-clip and separate rod from
manual lever (Fig. 96). (9) Remove screws attaching converter clutch mod­
ule to valve body and remove module and connecting
tube (Fig. 97).
(10) Turn valve body over so transfer plate is fac­
ing upward (Fig. 98). With valve body in this posi­
tion, valve body check balls will remain in place and
not fall out when transfer plate is removed.
(11) Remove screws attaching transfer plate to
valve body (Fig. 98).
SHUTTLE

VALVE PARK
END PLATE
ROD

Fig.
95
Removing
Manual And
Throttle
Levers

MANUAL
Fig.
96
Park
Rod Removal—32RH J912M78

Fig.
97 Converter
Clutch
Module
And
Connecting

Tube Removal/Installation—32RH (12) Remove transfer plate and separator plate
from valve body. Note position of filter and converter clutch solenoid for reference (Fig. 99).
(13) Position transfer plate on bench so separator
plate, filter and clutch solenoid are facing up. This
will avoid having rear clutch and rear servo check
balls fall out when plates are separated.

21
- 178
TRANSMISSION OVERHAUL—32RH

•
VALVE
BODY
TRANSFER
PLATE
J9121-181

Fig.
98
Valve
Body-
To- Transfer
Plate
Screw
Locations—32RH
Fig.
99 Transfer
Plate
Removal/Installation—32RH
(14) Remove screws attaching separator plate to
transfer plate.
(15) Remove converter clutch solenoid from separa­
tor plate (Fig. 100).
(16) Note position of filter, clutch solenoid and rear
clutch/rear servo check balls for assembly reference (Fig. 101).
(17) Remove shuttle valve end plate (Fig. 102).
(18) Remove shuttle valve E-clip and remove sec­
ondary spring and spring guides from end of valve (Fig. 102).
(19) Remove governor valve end plate (Fig. 103).
(20) Remove switch valve and pressure regulator
valve from valve body (Fig. 103).
Fig.
100
Removing
Converter
Clutch

Solenoid—32RH
SEPARATOR

J9121-

Fig.
101 Transfer And Separator Plates—32RH
(21) Remove throttle valve and spring, kickdown
valve and detent and manual valve from valve body (Fig. 103).
(22) Remove 1-2 and 2-3 shift valve governor plugs
from valve body (Fig. 103).
(23) Remove shuttle valve throttle plug, primary
spring and shuttle valve from valve body (Fig. 103).
(24) Remove 1-2 shift control valve and spring
from valve body (Fig. 104).

TRANSMISSION
OVERHAUL—32RH
21 - 171

E-CLIP
SHUTTLE

VALVE

Fig.
102 Shuttle
Valve
E-Clip
And
Secondary
Spring
Location—32RH
(25) Remove
2-3
shift valve
and
spring from valve
body
(Fig. 104).

(26) Remove
1-2
shift valve
and
spring from valve
body
(Fig. 104).
(27) Remove regulator valve
end
plate
(Fig. 104).

(28) Remove regulator valve line pressure plug,
pressure plug sleeve, throttle pressure plug
and
spring
(Fig. 104).
VALVE
BODY
CLEANING
AND
INSPECTION

The only serviceable valve body components
are:

• park lock
rod and
E-clip
• switch valve
and
spring
• pressure adjusting screw bracket • throttle valve lever
• manual shaft
• manual shaft seal, washer, E-clip
and
detent ball • fluid filter.
• converter clutch solenoid
The remaining valve body components
are
serviced
only
as
part
of a
complete valve body assembly.
Clean
the
valve body components
in a
parts clean­
ing solution only.
Do not use
gasoline, kerosene,
or
any type
of
caustic solution.
Dry the
parts with com­
pressed
air.
Make sure
all
passages
are
clean
and

free from obstructions.
Do
not use
rags
or
shop towels
to
wipe
off

valve body components. Lint from these materi­ als will adhere
to the
valve body components.
Lint will interfere with valve operation
and may
clog filters
and
fluid passages.
Inspect
the
throttle
and
manual valve levers
and

shafts.
Do not
attempt
to
straighten
a
bent shaft
or

correct
a
loose lever. Replace these components
if

worn, bent, loose
or
damaged
in any way.

Inspect
all of the
valve body mating surfaces
for

scratches, nicks, burrs,
or
distortion.
Use a
straight-
SHUTTLE

VALVE

END
PLATE

SWITCH
VALVE

LINE

PRESSURE

REGULATOR
VALVE
SECONDARY

SPRING
&
GUIDES

SHUTTLE
VALVE

PRIMARY
SPRING

SHUTTLE
VALVE

THROTTLE
PLUG

GOVERNOR
PLUG-

END
PLATE
J9121-50

Fig.
103
Control Valves
And
Governor
Plugs—32RH

21
- 180
TRANSMISSION OVERHAUL—32RH

•

REGULATOR VALVE

THROTTLE

PRESSURE

PLUG REGULATOR
VALVE

SPRING

SLEEVE

LINE

PRESSURE
PLUG
REGULATOR VALVE END
PLATE

SHIFT
VALVE END PLATE
2-3 SHIFT

VALVE
AND
SPRING
J912M80

Fig. 104 Shift Valves And Pressure Regulator Plugs—32RH
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with cro­
cus cloth. The cloth should be in sheet form and be
positioned on a surface plate, sheet of plate glass, or equally flat surface. However, if distortion is severe
or any surfaces are heavily scored, the valve body
will have to be replaced.

CAUTION:
The
throttle
valve, shuttle valve plug,
1-2

shift valve
and 1-2
governor plug
are
made
of
coated
aluminum.
These
components are
identified
in Figure
105
with
the
abbreviation (Alum.). Alumi­
num components
can be
identified
by the
dark

color
of the
special coating applied
to the
surface
(or
by
testing
with
a
magnet).
DO NOT
polish
or
sand
aluminum valves
or
plugs
with
any
type
of

material,
or
under
any
circumstances. This practice

will
remove the special
coating
and
cause
the

valves
and
plugs
to
stick
and
bind.

Inspect the valves and plugs for scratches, burrs,

nicks,
or scores. Also inspect the coating on the alu­ minum valves and plugs (Fig. 105). If the coating is
damaged or worn through, the valve (or valve body)
should be replaced. Aluminum valves and plugs must not be sanded or
polished under any circumstances. However, minor
burrs or scratches on steel valves and plugs can be removed with crocus cloth but do not round off the
valve or plug edges. Squareness of these edges is vi­
tally important. These edges prevent foreign matter from lodging between the valves, plugs and bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors. Re­ place the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken

coils.

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 han­dling.

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
REGULATOR VALVE
PRESSURE PLUG
SLEEVE
MODULE AND
CONNECTING
TUBE SHUTTLE VALVE
COVER
REGULATOR
VALVE THROTTLE PRESSURE PLUG
LINE
PRESSURE
ADJUSTING SCREW ADJUSTING
SCREW
BRACKET THROTTLE
PRESSURE
ADJUSTING SCREW SWITCH
VALVE AND
SPRING PRESSURE
REGULATOR VALVE AND
SPRING
2-3
SHIFT
VALVE GOVERNOR PLUG
SHUTTLE VALVE PLUG (ALUM.)
GOVERNOR VALVE
END
PLATE
MANUAL LEVER DETENT BALL
AND SPRING
J9121-369
Fig. 105
Valve
Body Components—32RH (Alum.
Indicates
Aluminum
Part)

21
- 182
TRANSMISSION OVERHAUL—32RH

• VAL VE
BODY
ASSEMBL
Y

CAUTION:
Do not
force
the 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.

Overtightening
can
distort
the valve body
resulting

in valve sticking,
cross
leakage and
unsatisfactory

operation. Tighten valve body
screws
to recom­ mended
torque
only.
(1) Lubricate valve body bores, valves and plugs
with transmission fluid.
(2) Insert rear clutch and rear servo check balls in
transfer plate (Fig. 100).
(3) Install filter screen in separator plate (Fig.

100).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep­ arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid
and insert solenoid in separator plate (Fig. 106). Fig. 106
Installing
Converter
Clutch
Solenoid—32RH

(6) Position valve body so internal passages and
check ball seats are facing upward. Then install
check balls in valve body (Fig. 107). There are a total
of seven check balls; The one large check ball is ap­
proximately 11/32 inch in diameter. The remaining
check balls are approximately 1/4 inch in diameter.
(7) Align and install assembled transfer and sepa­
rator plates on valve body. Install and tighten valve
body screws alternately in a diagnonal pattern to 4 N»m (35 in. lbs.) torque.
(8) Assemble converter clutch module and valves.
Then install assembly on valve body (Fig. 108).
(9) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring (Fig. 104). Insert as­
sembly in valve body and install end plate. Tighten
end plate screws to 4 N»m (35 in. lbs.) torqe. 1/4"
CHECK
BALLS
(6)

11/32"
CHECK
BALL
(1) J912M83
Fig. 107
Correct
Position
Of
Valve
Body Check
Baiis-32RH
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 104).
(11) Install 1-2 shift control valve and spring (Fig.
104)
(12) Install shuttle valve as follows: (a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second­
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve in place. Then compress
secondary spring and install E-clip in groove at end
of valve. (e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 103).
Tighten end plate screws to 4 N»m (35 in. lbs.)
torque.
(14) Install 1-2 and 2-3 valve governor plugs in
valve body (Fig. 103). Then install shuttle valve pri­
mary spring and throttle plug.
(15) Align and install governor plug end plate on
valve body and install end plate screws. Tighten screws to 4 N*m (35 in. lbs.) torque.
(16) Install manual valve (Fig. 103).
(17) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 103).
(18) Install pressure regulator valve and switch
valve in valve body.
(19) Install manual lever detent spring in housing.
Place detent ball on end of spring and push ball and spring into housing. Secure ball and spring with De­
tent Retainer 7684 or C-3765 (Fig. 94).

•

TRANSMISSION
OVERHAUL—32RH
21 - 183
MODULE
J932M23

Fig.
108 Converter
Clutch
Module
Components—32RH

(20) Insert line pressure adjusting screw in adjust­
ing screw bracket (Fig. 93).
(21) Install spring on end of line pressure regula­
tor valve.
(22) Install switch valve spring on tang at end of
adjusting screw bracket (Fig. 94).
(23) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and long bottom 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.
(24) Install converter clutch module and connect­
ing tube. Be sure long end of tube goes to module (Fig. 97). Tighten module screws to 4 Nrn (35 in.
lbs.) torque.
(25) Install throttle lever in valve body. Then in­
stall manual lever over throttle lever and start man­
ual lever into valve body. (26) Align manual lever detent with detent ball
and align lever arm with manual valve. Hold throt­
tle lever upward. Then press down on manual lever
until lever is fully seated. (27) Install manual lever seal, washer and retain­
ing E-clip. (28) Lubricate shaft of manual lever with light
coat of petroleum jelly. This will help protect seal lip
when manual shaft seal is installed. (29) Verify that throttle lever is aligned with end
of kickdown valve stem and that manual lever arm
is engaged in manual valve (Fig. 109).
Fig.
109 Manual And
Throttle
Lever

Alignment—32RH
(30) 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.