1993 DODGE TRUCK Service Repair Manual

21 - 184
TRANSMISSION
OVERHAUL—32RH
-
Fig. 110 Line Pressure Adjustment—32RH
Throttle
Pressure
Adjustment
Insert Gauge Tool C-3763 between the throttle le­
ver cam and the kickdown valve stem (Fig. 111).
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.
•

Fig. 111 Throttle Pressure Adjustment—32RH

TRANSMISSION ASSEMBLY AND ADJUSTMENT
Assembly
Tips

Do not allow dirt, grease, or foreign material to en­
ter the case or transmission components during as­ sembly. Keep the transmission case and components
clean. Also make sure the tools and workbench area
used for assembly are equally clean.
Shop towels used for wiping off your hands and ser­
vice tools must be made of lint free materials. Lint
will adhere to tranmission parts and could interfere with valve operation, or even restrict fluid passages.
Lubricate the transmission components with ATF

Plus,
or Dexron II™ during reassembly. Use petro­ leum jelly, Door Eze, or Ru-Glyde on seals and O-rings to ease installation.
Petroleum jejly can also be used to hold thrust
washers and plates in position during assembly oper­ ations. However, do not use chassis grease, bearing
grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can eventually block or restrict fluid passages and valve
operation. Use petroleum jelly only.
Do not force parts into place. Most of the transmis­
sion components are easily installed by hand when
properly aligned. If a part seems extremely difficult
to install, it is either misaligned or incorrectly as­ sembled. Also verify that thrust washers, thrust
plates and seal rings are correctly positioned before assembly. These parts can interfere with proper as­
sembly if mispositioned or "left out" by accident.

TRANSMISSION
ASSEMBLY PROCEDURE (1) Install rear servo piston, spring and spring re­
tainer. Compress rear servo spring and retainer with Compressor Tool C-3422-A or a large C-clamp.
(2) Install front servo piston, spring and rod guide.
Compress front servo rod guide with Valve Spring
Compressor C-3422-B and install servo snap ring.
The two pressures are interdependent because each
affects shift quality and timing. Each pressure ad­
justment must be performed properly and in the cor­ rect sequence. The correct sequence is line pressure adjustment first and throttle pressure adjustment
last.

Line
Pressure
Adjustment
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 110).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
The 33.4 mm (1-5/16 in,) setting Is an approxi­
mate setting. Because of manufacturing toler­
ances,
it may be necessary to vary from this
dimension to obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa). Turn­
ing the adjusting-screw counterclockwise increases
pressure while turning the screw clockwise decreases
pressure.

•

TRANSMISSION
OVERHAUL—32RH
21-185
(3) Examine bolt holes in overrunning clutch cam.
Note that one hole is not threaded (Fig. 112 This
hole must align with blank area in clutch cam bolt circle (Fig. 113).

Fig.
113 Location Of
Blank
Area in
Clutch
Cam
Seat
(in
Case)-32RH

(4) Mark location of non threaded hole in clutch
cam and blank area of case with paint stripe or
grease pencil (Fig. 114).
(5) Install overrunning clutch roller and spring as­
sembly in clutch cam (Fig. 114).
(6) Align and install overrunning clutch in case
(Fig. 114). Be sure cam is correctly installed. Bolt
holes in cam are slightly countersunk on one side. This side of cam faces rearward (toward
rear support).
(7) Verify that non threaded hole in clutch cam is
properly aligned (Fig. 114). Check alignment by threading a clutch cam bolt into each hole. Adjust cam position if necessary before proceeding.
(8) Install clutch cam bolts. Note that cam bolts
are shorter than rear support bolts. Tighten cam bolts to 17 N»m (150 in. lbs.) torque.
(9) Lubricate overrunning clutch rollers with
transmission fluid. (10) Install rear band reaction pin (Fig. 105). Be
sure pin is fully seated in case.

Fig.
114 Overrunning
Clutch
And Rear
Band
Pin Installation—32RH
(11) Install rear band in case (Fig. 115). Twin lugs
on band seat against reaction pin and single lug
faces band lever.
(12) Install low-reverse drum as follows (Fig. 115): (a) Lubricate overrunning clutch race (on hub of
drum) with transmission fluid. (b) Guide drum through rear band.
(c) Tilt drum slightly and start clutch race into
overrunning clutch rollers.
(d) Rotate drum in clockwise direction and push
drum inward until it seats in overrunning clutch.

Fig.
115 Installing Rear
Band
And
Low-Reverse
Drum—32RH

(13) Install rear band lever and pivot pin (Fig.

116).
Be sure pin is fully seated in case.

21
- 186
TRANSMISSION
OVERHAUL—32RH

Fig.
116 Installing Rear
Band
Lever
And Pivot
Pin-32RH
(14) Hold low-reverse drum in position and install
rear support. Align support with punch marks made
during disassembly.
(15) Install and tighten rear support bolts to 17
N*m (150 in. lbs. or 13 ft. lbs.) torque.
(16) Install snap ring that retains low-reverse
drum to hub of rear support (Fig. 117).

Fig.
117 Installing
Low-Reverse
Drum
Snap
Ring—32RH

(17) Lubricate output shaft, rear support bore and
low-reverse drum hub with transmission fluid. (18) Install assembled output shaft and planetary
geartrain in case (Fig. 118).
(19) Align drive lugs on rear planetary gear with
slots in low-reverse drum (Fig. 119). Then seat plan­
etary assembly in drum.
(20) Lubricate governor components and park gear
seal rings with transmission fluid. •

Fig.
118 Installing Output Shaft/Planetary Geartrain—32RH

Fig.
119
Aligning/Seating
Rear Planetary In Low-
Reverse
Drum—32RH
(21) Install governor filter in park gear and install
governor body on gear (Fig. 120). Align governor
body on gear using marks made at disassembly.
(22) Install new seal rings on hub of park gear
(Fig. 120). Be sure ring (or rings) with hooked ends
are properly connected.
(23) Install governor weight assembly in governor
body. Be sure governor weight snap rings are se­ curely seated.
(24) Align and install governor/park gear assembly
on output shaft. Note that output shaft in current
transmission is spotfaced for governor valve end clearance (Fig. 120). Shaft must be indexed so
that small end of governor valve will seat in this spotface. Install governor body and park as fol­
lows to ensure proper alignment and operation.

•

TRANSMISSION
OVERHAUL—32RH
21 - 187 (a) Rotate output shaft until spotface (at gover­
nor valve shaft hole) is facing upward (Fig. 120). (b) Position valve bore in governor body over
spotface on output shaft (Fig. 120). Then align
valve shaft holes in governor body and output shaft.
(c) Align splines in output shaft and park gear

hub.
(d) Carefully push assembly into place in rear
support (Fig. 121). (e) Verify that governor valve shaft holes in out­
put shaft and governor body are still in alignment.
Reposition governor body and park gear if align­
ment is not correct.
(f) Tighten bolts attaching governor body to park
gear to 11 N*m (95 in. lbs.) torque.
OUTPUT

SHAFT
GOVERNOR BODY
GOVERNOR VALVE
BORE

J9221-52

Fig.
120
Governor
Valve
And Output Shaft Spotface
Alignment—32RH

GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR
VALVE
SHAFT
BORE

J9121-130

Fig.
121 Installing
Governor
Body
And
Park
Gear-32RH
in valve and in output shaft. If valve shaft binds,
governor/park gear is misaligned.
E-CLIP
(2
REQ'D)
GOVERNOR
VALVE

\-
SHAFT
Fig.
122 Installing
Governor
Valve
And Shaft—32RH (26) Rotate output shaft until opposite end of gov­
ernor valve shaft is facing upward. Then install re-
mainig E-clip on governor valve shaft (Fig. 123). Be
very sure both E-clips are firmly seated on shaft.

GOVERNOR VALVE SHAFT
J9121-188

Fig.
123
Securing
Governor
Valve
Shaft—32RH
(27) Install snap ring that retains governor body
on output shaft (Fig. 124).
(28) Install output shaft thrust plate on shaft hub
(Fig.
125).
Use petroleum jelly to hold thrust plate in
place.
(29) Check input shaft seal rings (Fig. 126). Verify
that diagonal-cut ends of teflon seal ring are properly
joined and ends of metal ring are correctly hooked to­ gether. Also be sure rings are installed sequence shown.
(30) Check rear clutch thrust washer. Use addi­
tional petroleum jelly to hold washer in place if nec­ essary. (25) Install first E-clip on governor valve shaft.
Then install governor valve and shaft in governor
body (Fig. 122). Be sure valve shaft moves freely

21
- 188
TRANSMISSION
OVERHAUL—32RH

•

Fig.
124 Installing
Governor
Body
Snap
Ring—32RH
Fig.
125 Installing Output Shaft Thrust PIate-32RH
Fig.
126 input Shaft
Seal
Ring
Location-32RH
(31) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 127). Rotate front
clutch retainer back and forth until completely
seated on rear clutch.
Fig.
127
Assembling
Front And Rear
Clutch

Units-32RH
(32) Coat output shaft thrust washer with petro­
leum jelly. Then install washer in rear clutch hub (Fig. 128). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer faces rearward (toward output shaft) as shown.
Also note that washer only fits one way in clutch hub.

Fig.
128 Installing Output Shaft Thrust
Washer-32RH

(33) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 129). This will make installa­
tion on front planetary easier.
(34) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to in­ stall if transmission is as close to upright position as
possible.
(35) Install front and rear clutch units as assembly
(Fig. 130). Align rear clutch with front annulus gear
and install assembly in driving shell. Be sure out­
put shaft thrust washer and thrust plate are not displaced during installation.

•

TRANSMISSION
OVERHAUL—32RH
21 - 189

Fig.
129
Aligning
Rear
Clutch
Disc Lugs—32RH
(36) Carefully work assembled clutches back and
forth to engage and seat rear clutch discs on front annulus gear. Verify that front clutch drive lugs are
fully engaged in slots of driving shell after installa­
tion.

J9121-124

Fig.
130 Installing Front/Rear
Clutch
Assemblies—32RH

(37) Slide front band over front clutch retainer
(Fig. 131).
(38) Insert front band reaction pin part way into
case (Fig. 131). (39) Install front band lever, strut, lever pin and
adjusting screw (Fig. 132).
(40) Tighten front band adjusting screw until band
just grips clutch retainer. Verify that front/rear clutches are still seated before continuing.
Fig.
131 Installing Front
Band
And Reaction

Pin-32RH

BAND
BAND
Fig.
132 Front
Band
Linkage
Installation—32RH (41) Coat band lever pin access plug with sealer
and install plug in converter housing (Fig. 133).

Fig.
133 Installing Front
Band
Reaction Pin
Access
Plug-32RH

(42) Check reaction shaft support hub. Verify that
seal rings are hooked together and that front clutch

21
- 190
TRANSMISSION OVERHAUL—32RH

• thrust washer is properly positioned (Fig. 134). Use
extra petroleum jelly to hold thrust washer in place
if necessary.

SEAL
RINGS
J9121-194

Fig.
134 Reaction Shaft
Support
Seal
Rings
And Front
Clutch
Thrust
Washer
Position—32RH (43) Thread two Pilot Stud Tools C-32S8-B into
bolt holes in oil pump flange (Fig. 135).
(44) Align and install oil pump gasket (Fig. 135).
Fig.
135 Installing Pilot
Studs
And Oil
Pump

Gasket-32RH
(45) Lubricate oil pump seals with transmission
fluid, petroleum jelly, or Ru-Glyde.
(46) Install oil pump (Fig. 136). Align and position
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then install two or three pump bolts to hold pump in
place.
(47) Remove pilot stud tools and install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 N-m (15 ft-lbs).
Fig.
136 Installing Oil
Pump
And Reaction Shaft

Support-32RH
(48) Measure input shaft end play (Fig. 137). At­
tach dial indicator to converter housing. Position in­ dicator plunger against input shaft and zero
indicator. Move input shaft in and out and record
reading. End play should be 0.56 - 2.31 mm (0.022 - 0.091 in.). If end play is incorrect, change output
shaft thrust washer and/or thrust plate.
Fig.
137
Checking
Input Shaft End Play-32RH
(49) Make sure neutral switch has not been in­
stalled in case. Remove switch if necessary as it will
interfere with valve body installation.
(50) Install new seal rings on accumulator piston
(Fig. 138). Lubricate accumulator piston, seals and
accumulator bore with transmission fluid. (51) Install accumulator piston and spring (Fig.
138) in case.
(52) Place valve body manual lever in low to move
park lock rod rearward.

•
Fig. 138 installing Accumulator Piston And Spring—32RH
(53) Position valve body on case. Work park rod
past sprag and install valve body-to-case bolts finger tight.
(54) Install neutral switch in case. Tighten switch
to 34 N-m (25 ft. lbs.) torque.
(55) Align valve body on case (Fig. 139). Tighten
valve body-to-case bolts alternately and evenly to 12
N»m (105 in. lbs.) torque. Start at center and work
outward when tightening bolts. Do not overtighten
valve body bolts. This could result in distortion and cross leakage after Installation..

VALVE

Fig. 139 Installing
Valve
Body—32RH
—
TRANSMISSION
OVERHAUL—32RH
21 - 1S1 (56) Install new filter on valve body. Tighten filter
screws to 4 N»m (35 in. lbs.).
(57) Position new extension housing gasket on
transmission case. Use petroleum jelly to hold gasket in place.
(58) Install rear bearing and snap ring on output
shaft. (59) Install extension housing on transmission
case. Tighten housing fasteners to 33 N»m (24 ft.

lbs.).
Be sure park lock rod is properly engaged in sprag before tightening fasteners.
(60) Adjust front/rear bands as follows: (a) Loosen locknut on each band adjusting screw
4-5 turns.
(b) Tighten both adjusting screws to 8 N*m (72

in.
lbs.).
(c) Back off front band adjusting screw 2-1/2
turns and rear band adjusting screw 4 turns.
(d) Hold each adjusting screw in position and
tighten locknuts to 34 N*m (25 ft. lbs.).
(61) Install new pan gasket on transmission and
install oil pan. Tighten pan bolts to 17 N«m (13 ft.

lbs.).
(62) Turn transmission over.
(63) Install new manual lever shaft seal in case.
Use 15/16 deep well socket to install seal.
(64) Install throttle valve and manual valve levers
on shaft. (65) Lubricate converter hub with transmission
fluid and carefully install converter. Turn converter
back and forth until seated. Be sure converter hub slots are fully seated in oil pump gear lugs.
(66) Secure converter in oil pump before mounting
transmission on jack and before moving transmission
back under vehicle. Use metal strapping or small C-clamp to hold converter in place. Attach strapping
or clamp to converter housing.

CAUTION:
The
transmission
cooler
and
lines
must
be
reverse
flushed
if
overhaul
corrected
a
malfunc­

tion that
generated
sludge,
metal
particles,
or
clutch
friction
material.
The
torque
converter
should

also
be
replaced
if
contaminated
by the
same
mal­

function.
Debris
and
residue
not
flushed
from
the
cooler
and
lines
will
flow
back
into the
transmission

and
converter.
The
result
could
be a
repeat
failure

and
shop
comeback.