1993 DODGE TRUCK Service Repair Manual

21
- 208
TRANSMISSION OVERHAUL—36RH/37RH

•

SNAP
RING
PISTON

SEAL
PISTON
PLUG
SPRING
RETAINER
SNAP

RING

PISTON
CUSHION

SPRING
PISTON

SPRING
J9121-64

Fig.
60 Rear
Servo
Components—36RH/37RH
OIL PUMP AND REACTION SHAFT SUPPORT
OVERHAUL

DISASSEMBLING PUMP AND SUPPORT (FIG.
61)
(1) Mark position of support with scriber.
(2) Remove support bolts and separate support and
pump body (Fig. 61). (3) Remove O-ring seal from pump body. (4) Remove seal rings and thrust washer from re­
action shaft support. (5) Clean pump and support components with sol­
vent and dry them with compressed air.
INSPECTING PUMP AND SUPPORT Inspect the pump and support components. Replace
the pump or support if the seal ring grooves or ma­ chined surfaces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or
damaged. Inspect the fiber thrust washer. Replace
the washer if worn or damaged.
Inspect the pump and reaction shaft bushings. Re­
place the bushings only if heavily worn, scored or
damaged. It is not necessary to replace the bushings
unless they are actually damaged or worn.
Install the gears in the pump body and measure
end clearance with a feeler gauge and straightedge (Fig. 62). Clearance should be 0.025 to 0.064 mm
(0.001 to 0.0025 in.).
Fig.
61 Oil
Pump
And Reaction Shaft
Components—36RH/37RH

•

TRANSMISSION
OVERHAUL—36RH/37RH
21 - 209 Measure side clearances with feeler gauge (Fig.

63).
Clearance between gear teeth and between outer
gear and pump body should be 0.89 to 1.90 mm (0.0035 to 0.0075 in.).

STRAIGHTEDGE
PUMP
Fig.
62
Checking Pump
Gear End Clearance

REPLACING
OIL
PUMP BUSHING
(1) Position pump housing on clean, smooth sur­
face with gear cavity facing down.
(2) Remove bushing with Tool Handle C-4171 and
Bushing Remover SP-3550 (Fig. 64).
(3) Assemble Tool Handle C-4171 and Bushing In­
staller SP-5118 (Fig. 64). (4) Place bushing on installer tool and start bush­
ing into shaft (Fig. 64).
(5) Tap bushing into place until Installer Tool SP-
3550 bottoms in pump cavity (Fig. 64). Keep tool and
bushing square with bore. Do not allow bushing to
become cocked during installation.
(6) Stake pump bushing in two places with blunt
punch. Remove burrs from stake points with knife
blade (Fig. 65).

REPLACING
REACTION SHAFT SUPPORT

BUSHING
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushing Remover SP-5301 (Fig. 66). (2) Hold cup tool firmly against reaction shaft.
Thread remover tool into bushing as far as possible
by hand.
(3) Using wrench, thread remover tool an addi­
tional 3-4 turns into bushing to firmly engage tool.
(4) Tighten tool hex nut against cup tool to pull
bushing from shaft. Clean all chips from shaft and support after bushing removal.
(5) Place reaction shaft support upright on a clean,
smooth surface.
(6) Assemble Bushing Installer Tools C-4171 and
SP-5302 (Fig. 66). Then slide new bushing onto in­
staller tool.
J8921-388
Fig.
63
Checking Pump
Gear
Side
Clearances
(7) Start bushing in shaft. Tap bushing into shaft
until installer tool bottoms against support flange
(Fig. 66).
(8) Clean reaction shaft support thoroughly after
bushing replacement (to remove any chips).

ASSEMBLING
OIL
PUMP
AND
REACTION SHAFT SUPPORT

(1) Lubricate pump gears with transmission fluid
and install them in pump body.
(2) Install new thrust washer and seal rings on re­
action shaft support. Lubricate seal rings with trans­
mission fluid or petroleum jelly.
(3) Align and install reaction shaft support on
pump body.

21
- 210
TRANSMISSION
OVERHAUL-36RH/37RH

•

SPECIAL
TOOL

C-4171
BUSHING

m
REMOVAL

PUMP
HOUSING

SPECIAL
TOOL
C-4171
SPECIAL
TOOL

SP-3550

BUSHING

SPECIAL
TOOL
SP-5118
J9221-244

Fig.
64 Oil
Pump Bushing
Replacement—36RH/
37RH
mm

Fig.
65 Staking And Deburring Oil
Pump Bushing
(4) Install bolts attaching reaction shaft support to
pump. Tighten bolts to 20 N«m (175 in. lbs.) torque.
(5) Install new pump seal with Seal Installer
C-3860-A and Tool Handle C-4171.
(6) Install new O-ring on pump body. Lubricate oil
seal and O-ring with transmission fluid or petroleum
jelly.
(7) Set pump and support aside for assembly in­
stallation.

FRONT
CLUTCH OVERHAUL

FRONT CLUTCH DISASSEMBLY (1) Remove waved snap ring and remove pressure
plate, clutch plates and driving discs (Fig. 67).
SPECIAL

TOOL
SP-119
SPECIAL

TOOL

C-4171

SPECIAL
TOOL
SP-5302
BUSHING BUSHING

X
REACTION
SHAFT

BUSHING

REMOVAL
BUSHING
INSTALLATION
J9221-245

Fig.
66 Reaction Shaft
Bushing
Replacement—36RH/37RH

(2) Compress clutch piston retainer and springs
with Compressor Tool C-3863-A (Fig. 68).
(3) Remove piston snap ring and spring retainer
(Fig. 67).
(4) Remove piston springs. Note number and po­
sition of piston springs for assembly reference.
(5) Remove compressor tool and remove clutch pis­
ton.
(6) Remove and discard clutch piston seals. Also
discard spring retainer snap ring.
FRONT CLUTCH CLEANING AND INSPECTION Clean and inspect the front clutch components. Re­
place the clutch discs if warped, worn, scored, burned or charred, the lugs are damaged, or if the facing is
flaking off. Replace the steel plates if heavily scored,
warped, or broken. Be sure the driving lugs on the discs and plate are also in good condition. The lugs
must not be bent, cracked or damaged in any way.
Replace the piston springs and spring retainer if ei­
ther are distorted, warped or broken. Check the lug grooves in the clutch piston retainer.
The steel plates should slide freely in the slots. Re­
place the piston retainer if the grooves are worn or damaged. Also check action of the check ball in the
piston retainer. The ball must move freely and not stick.
Replace the retainer bushing if worn, scored, or
there is any doubt 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.

4 _
,
TRANSMISSION
OVERHAUL—3IRH/37RH
21 - 211

PISTON
SEAL

REACTION
PLATE
J9121-65

SPECIAL
TOOL

C-3863-A

Fig.
67 Front
Clutch
Components—36RH/37RH
(5) Install new bushing until installer head bot­
toms against retainer (Fig. 69).
(6) Remove installer tools and clean retainer thor­
oughly.
RH290

Fig.
68
Removing
Front
Clutch
Spring
Retainer
Snap
Ring-36RH/37RH
REPLACING
FRONT
CLUTCH
RETAINER

BUSHING

(1) Assemble Tool Handle C-4171 and Bushing Re­
mover SP-3629 (Fig. 69). (2) Insert remover tool in bushing and drive bush­
ing straight out of piston retainer. (3) Mount Bushing Installer SP-5511 on tool han­
dle (Fig. 69).
(4) Slide new bushing onto installer head and start
bushing in retainer.
SPECIAL

TOOL-

C-4171

FRONT
CLUTCH
RETAINER
It

BUSHING

REMOVAL
SPECIAL

TOOL

SP-3629

SPECIAL
TOOL

C-4171
SPECIAL

TOOL

SP-5511
J9221-247

Fig.
69 Front
Clutch
Retainer
Bushing
Replacement—36RH/37RH

ASSEMBLING
FRONT
CLUTCH
(1) Soak clutch discs in transmission fluid.
(2) Lubricate new inner and outer piston seals
with Ru-Glyde, or Door Ease. (3) Install new seals on clutch piston. Be sure seal
lips face interior of retainer.

21 - 212
TRANSMISSION OVERHAUL—36RH/37RH

• (4) Install clutch piston in retainer. Use twisting
motion to seat piston in retainer. Do not force pis­
ton straight in. This could fold seals over caus­
ing leakage and clutch slip.
(5) Install clutch piston springs. If clutch has nine
springs, position springs as shown (Fig. 70). 9
SPRING
CLUTCH

11
SPRING CLUTCH

13
SPRING CLUTCH
J9221-260

Fig.
70 Front
Clutch
Spring
Position—36RH/37RH
(6) Install retainer on piston springs.
(7) Compress spring retainer and piston springs
with Compressor Tool C-3863-A.
(8) Install new spring retainer snap ring and re­
move compressor tool.
(9) Lubricate clutch plates and pressure plate with
transmission fluid.
(10) Install clutch plates and discs. Install steel
plate followed by a disc until 4 plates and discs are installed.
(11) Install pressure plate and waved snap ring.
(12) Check clutch pack clearance (Fig. 71). Clear­
ance between waved spring and pressure plate
should be 2.08 to 3.83 mm (0.082 to 0.151 in.). If
clearance is incorrect, clutch plates, discs, snap ring
and/or pressure plate will have to be changed.

REAR
CLUTCH OVERHAUL FEELER GAUGE
RH288

Fig.
71
Measuring
Front
Clutch
Pack
Clearance
(Typical)
(2) Remove outer pressure plate and steel plates
and discs. (3) Remove inner pressure plate, wave spring,
spacer ring and piston spring. (4) Remove clutch piston and piston retainer from
clutch retainer. Bump clutch retainer on a wood
block to dislodge piston and retainer.
(5) Remove input shaft thrust washer.
(6) Remove input shaft snap ring and press shaft
out of clutch retainer.
(7) Remove and discard clutch piston seals.
(8) Do not remove shaft seal rings unless they are
obviously damaged (broken, cracked).

REAR
CLUTCH CLEANING
AND
INSPECTION
Clean the clutch components with solvent and dry
them with compressed air.
Replace the clutch discs if warped, worn, scored,
burned/charred, the lugs are damaged, or if the fac­ ing is flaking off. Replace the steel plates and the pressure plate if
heavily scored, warped, or broken. Be sure the driv­
ing lugs on the discs and plates are also in good con­ dition. 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
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.
REAR
CLUTCH DISASSEMBLY
(FIG. 72)
(1) Remove clutch pack select fit snap ring.

# — .—.—, , TRANSMISSION
OVERHAUL-3IRH/37RH
21 - 213

Fig.
72
Rear
Clutch
C
Also check action
of the
retainer check ball.
The
ball
must move freely
and not
stick.
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 damaged.
Check thrust washer condition. Washer thickness
should
be 1.55 to 1.60 mm
(0.061
to
0.063
in.). Re­

place
the
washer
if
worn
or
damaged.
Check condition
of the two
seal rings
on the
input
shaft
and the
single seal ring
on the
piston retainer.
Replace
the
seal rings
if
worn
or
damaged.
Check
the
input shaft
for
wear,
or
damage. Replace
the shaft
if
worn, scored
or
damaged
in any way.

ASSEMBLING
REAR
CLUTCH
(FIG. 72)

(1) Soak clutch discs
in
transmission fluid.
(2) Install
new
seal rings
on
input shaft
and
piston
retainer
(Fig. 73).

(3) Press input shaft into retainer. Secure shaft
with snap ring.
Use new
snap ring
if old one is
dis­
torted,
or
damaged.
(4) Install
new
seals
on
clutch piston. Lubricate
piston seals with Ru-Glyde,
or
Door Ease.
Be
sure seal lips face input shaft.
(5) Install clutch piston
in
retainer.
Use
twisting
motion
to
seat piston
in
retainer.
Do not
push pis­
ton straight
in.
This could distort seals causing
leakage
and
clutch slip.
(6) Install thrust washer
on
retainer
(Fig. 72). Use

petroleum jelly
to
hold thrust washer
in
place.
(7) Install assembled piston retainer
in
clutch
re­

tainer
(Fig. 72).
-36RH/37RH

Fig.
73
Input Shaft
And
Retainer
Seal
Ring

Locations-36RH/37RH (8) Install piston spring, spacer ring
and
wave
spring
in
clutch retainer.
Be
sure wave spring
is

fully seated.
Tap
spring into place
if
necessary.
(9) Lubricate clutch plates with transmission fluid.
(10) Install inner pressure plate.
(11) Install first clutch disc followed
by a
steel
plate until
all
discs
and
plates
are
installed.
(12) Install outer pressure plate
and
snap ring. (13) Check clutch pack clearance with feeler gauge
(Fig.
74).
Clearance should
be 0.63 to 1.14 mm
(0.025
to 0.045
in.). A low
limit clearance
is
preferred.
(14)
If
clutch pack clearance
is
incorrect, clutch
pack snap ring, pressure plate, steel plates
and
discs
will have
to be
replaced.

21
- 214
TRANSMISSION
OVERHAUL—3SRH/37RH

SELECTIVE

SNAP
RING

FEELER

GAUGE

RH295

Fig.
74
Measuring
Rear
Clutch
Pack
Clearance
(Typical)
PLANETARY
GEAR TRAIN AND OUTPUT SHAFT

OVERHAUL

GEARTRAIN AND
SHAFT INSPECTION
Clean the output shaft and geartrain components
(Fig. 75). Use parts cleaning solvent and dry with
compressed air.
Remove one of the snap rings that retain the sun
gear in the driving shell. Then remove the sun gear and thrust plate.
Check sun gear and driving shell condition. Re­
place the sun gear as an assembly if the gear teeth are chipped or worn. Also replace the gear as an as-
SNAP
RING
(SELECTIVE)
THRUST

WASHER
FRONT

ANNULUS GEAR
sembly if the bushings are scored or worn. The sun
gear bushings are not serviceable. Replace the thrust
plate if worn, or severely scored. Replace the driving shell if distorted, cracked, or damaged in any way.
Inspect the planetary gear sets and annulus gears.
The pinion gears, pinion shafts, pinion washers and shaft retaining pins are all serviceable and can be re­
placed if worn or damaged. However, if a pinion car­ rier is damaged, the entire planetary gear set must
be replaced as an assembly.
Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash­ ers if cracked, scored or worn.
Inspect the machined surfaces of the output shaft.
Be sure the oil passages are open and clear. Replace
the shaft if scored, pitted, or damaged.
PLANETARY GEARTRAIN ASSEMBLY AND
ADJUSTMENT
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly to hold parts in place and to lubricate output shaft bushing surfaces, thrust washers and thrust

plates.

(2) Install front snap ring on sun gear and install
gear in driving shell. Then install thrust plate over
sun gear and against rear side of driving shell. In­ stall rear snap ring to secure sun gear and thrust
plate in driving shell.
(3) Install rear annulus gear on output shaft (Fig.

76).

(4) Install thrust plate in annulus gear (Fig. 77).
Be sure plate is seated on shaft splines and against gear.
DRIVING SHELL

THRUST

PLATE
REAR

PLANETARY GEAR
ASSEMBLY
REAR
ANNULUS

GEAR

FRONT

PLANETARY GEAR
ASSEMBLY

THRUST
PLATE

OUTPUT
SHAFT
LOW-REVERSE

DRUM
J9121-67

Fig.
75 Planetary
Geartrain
Components—36RH/37RH

•

TRANSMISSION
OVERHAUL—36RH/37RH
21 - 215

OUTPUT
SHAFT
J9121-68

Fig.
76 Installing Rear
Annulus
Gear On Output
Shaft-36RH/37RH
THRUST

PLATE

J9121-69

Fig.
77 Installing Rear
Annulus
Thrust Plate—36RH/ 37RH
(5) Install rear planetary gear in rear annulus
gear (Fig. 78). Be sure planetary carrier is seated against annulus gear.
REAR
ANNULUS GEAR REAR
PLANETARY GEAR

J9121-70

Fig.
78 installing Rear Planetary Gear—36RH/37RH (6) Install tabbed thrust washer on front face of
rear planetary gear (Fig. 79). Seat washer tabs in matching slots in face of gear carrier. Use extra pe­
troleum jelly to hold washer in place if desired.

REAR
PLANETARY GEAR
WASHER
J9121-71

Fig.
79 Installing Rear Planetary Thrust
Washer-36RH/37RH

(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
(8) Install sun gear and driving shell on output
shaft (Fig. 80). Seat shell against rear planetary
gear. Verify that thrust washer on planetary gear
was not displaced during installation.

OUTPUT
SHAFT DRIVING
SHELL REAR
PLANETARY
GEAR
SUN
GEAR
OUTPUT

SHAFT

J9121-72

Fig.
80 Installing Sun Gear And Driving
Shell-36RH/37RH

(9) Install tabbed thrust washer in driving shell
(Fig. 81). be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
washer in place if desired.
(10) Install tabbed thrust washer on front plane­
tary gear (Fig. 82). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.