1993 DODGE TRUCK Service Repair Manual

21
- 248
TRANSMISSION
0VERHAUL-42RH

REAR

CLUTCH
PISTON CLUTCH
PISTON
SEALS
OUTPUT

SHAFT
THRUST
WASHER
(METAL)
INPUT

SHAFT SNAP RING REAR

CLUTCH

RETAINER
INPUT

SHAFT
-REAR

CLUTCH

.
THRUST

^
/ SHAFT
WA|HER
/
FRONT
(FIBER)

SHAFT
SEAL
REAR RING
-M„u
SEAL (TEFLON)
C^H

RING
PACK

(METAL) SNAP
RING

(SELECTIVE)
PISTON
SPRING
BOTTOM

PRESSURE PLATE
CLUTCH
DISCS
(4)
TOP
PRESSURE PLATE

J9121-539

Fig.
60
Rear
Clutch
Components—42RH

Fig.
61
Removing/Installing Input Shaft
Snap
Ring-42RH
Check
the
input shaft
for
wear,
or
damage. Replace
the shaft
if
worn, scored
or
damaged
in any way.

REAR
CLUTCH ASSEMBLY
(1) Soak clutch discs
in
transmission fluid.
(2) Install
new
seal rings
on
clutch retainer
hub

and input shaft (Figs.
63 and 64).
J912M50

Fig.
62
Removing
Input Shaft From Rear
Clutch
Retainer—42RH (a)
Be
sure clutch
hub
retainer seal ring
is
fully
seated
in
groove
(Fig. 63).
Ring must
not be

twisted,
or
distorted. (b) Note that input shaft front seal ring
is
teflon
and rear seal ring
is
metal (Fig. 64).
Be
sure cham­
fered ends
of
teflon ring
are
properly joined
and

that ends
of
rear ring
are
securely hooked together.
(c) Lubricate retainer
and
shaft seal rings with
light coat
of
petroleum jelly after installation.

•

TRANSMISSION
OVERHAUL-42RH
21 - 24S
J9121-538

Fig.
63 Installing Rear
Clutch
Retainer And Input

Shaft
Seal
Rings—42RH

J912M51
Fig.
64 input Shaft
Seal
Ring
Identification—42RH
(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then press input shaft into retainer (Fig. 65).
(4) Install input shaft retaining ring (Fig. 61).
(5) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
(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.
Fig.
65
Pressing
Input Shaft Into Rear
Clutch

Retainer—42RH (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.
(8) Install piston spring in retainer and on top of
piston (Fig. 56). Concave side of spring faces up as shown.
(9) Install wave spring in retainer (Fig. 66). Be
sure spring is completely seated in retainer groove.

Fig.
66
Piston
And Wave
Spring
Position—42RH
(10) Install bottom pressure plate (Fig. 60). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.

21
- 250
TRANSMISSION 0VERHAUL-42RH
—

Fig.
67
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. 68). Use enough petroleum
jelly to hold washer in place.
(16) Set rear clutch aside for installation during fi­
nal assembly.

PLANETARY GEAR TRAIN AND INTERMEDIATE
SHAFT OVERHAUL

GEARTRAIN DISASSEMBLY (FIG* 69) (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. •

Fig.
68 Installing Rear
Clutch
Thrust Washer—42RH (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 intermediate
shaft.
(10) Remove snap rings securing annulus gears to
supports. Then separate each gear from 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 part that is worn or damaged. Do not attempt to reuse these

parts.

Inspect the intermediate shaft carefully. Pay par­
ticular attention to the machined bushing/bearing surfaces on the shaft.
Replace the intermediate shaft if any machined
surfaces are scored, pitted, or damaged in any way.
Also replace the shaft if the splines are damaged, or exhibits cracks at any location. Be sure the select spacer groove on the shaft is in good condition. Trial
fit the spacer if necessary.
(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 in­
stalled. 4 clutch discs and 3 metal plates are
required.
(12) Install top pressure plate (Fig. 60).
(13) Install selective snap ring (Fig. 60). Be sure
snap ring is fully seated in retainer groove. (14) Measure clutch pack clearance (Fig. 67).
Clearance should be 0.64 to 1.14 mm (0.025 to 0.045

in.).
If clearance is incorrect, steel plates, discs, snap
ring and pressure plates may have to be changed (Fig. 53).

#
, , . , _
TRANSMISSION 0VERHAUL-42RH
21 - 251

SELECT
FRONT

FIT ANNULUS
PLANETARY SNAP

SNAP
RING RING SUPPORT

SNAP
RING
FRONT

ANNULUS
GEAR
FRONT

PLANETARY THRUST

WASHERS
SUN

GEAR
SUN

GEAR

SPACER
DRIVING SHELL

FRONT
THRUST
PLATE
FRONT

ANNULUS
THRUST

WASHER

DRIVING
SHELL
REAR

THRUST PLATE OVERDRIVE
PISTON
RETAINER INTERMEDIATE
SHAFT THRUST PLATE DRIVING

,
SHELL
CLUTCH
CAM BOLTS
INTERMEDIATE SHAFT
Fig.
69
Transmission
Planetary Gear Train—42RH
J9221-18

PLANETARY
GEARTRAIN
ASSEMBLY
(1) Lubricate intermediate shaft and planetary
components with transmission fluid. Use petroleum
jelly to lubricate and hold thrust washers and plates in position. (2) Assemble rear annulus gear and support if dis­
assembled. Be sure support snap ring is seated and
that shoulder side of support faces rearward.
(3) Install rear thrust washer on rear planetary
gear (Fig. 70). 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. 70).
(5) Install assembled rear planetary and annulus
gear on intermediate shaft (Fig. 71). Verify that as­
sembly is fully seated on shaft.
(6) Install front thrust washer on rear planetary
gear (Fig. 72). Use enough petroleum jelly to hold
washer on gear.
(7) Install spacer on sun gear (Fig. 73).
(8) Install thrust plate over sun gear and on top of
spacer (Fig. 74). Note that thrust plates are inter­
changeable. Use either plate on sun gear and rear of
driving shell.
REAR

ANNULUS
GEAR

TABBED
THRUST

WASHER

REAR

PLANETARY

J9121-156

Fig.
70
Assembling
Rear
Annulus
And Planetary
Gear-42RH
(9) Insert sun gear into driving shell (Fig. 75).
(10) Hold sun gear in position and install rear
thrust plate. Plate goes over sun gear at rear of driv­ ing shell (Fig. 75).

21

- 252 TRANSMISSION OVERHAUL-42RH
•

REAR
ANNULUS

AND
PLANETARY
GEAR
ASSEMBLY

INTERMEDIATE
SHAFT

J9121-275

Fig.
71 installing
Assembled
Rear
Annulus
And Planetary Gear On
Intermediate
Shaft—42RH
FRONT

TABBED
THRUST

WASHER
REAR

PLANETARY
GEAR
J9121-158

Fig.
72 Installing Rear Planetary Front Thrust
Washer-42RH

SUN
GEAR SUN GEAR

SPACER
J912M59

Fig.
73 Installing Sun Gear Spacer—42RH
(11) Position wood block on bench and support sun
gear on block (Fig. 76). This makes it easier to align
THRUST
PLATE
Fig.
74 Installing
Spacer
And Thrust
Plate
On Sun
Gear-42RH

SUN

DRIVING
GEAR SHELL
REAR

THRUST
PLATE
J9121-162

Fig.
75 Installing Sun Gear And Rear Thrust
Plate
In
Driving
Shell-42RH
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.
76 Supporting Sun Gear On
Wood
Block-42RH

•

TRANSMISSION
OVERHAUL-42RH
21 - 253 (12) 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. 77).

Fig.
77 Installing Sun Gear
Lock
Ring—42RH

(13) Install assembled driving shell and sun gear
on intermediate shaft (Fig. 78).

Fig.
78 Installing
Assembled
Sun Gear And Driving
Shell
On
Intermediate
Shaft—42RH
(14) Install rear thrust washer on front planetary
gear (Fig. 79). Use enough petroleum jelly to hold
washer on gear and be sure washer tabs are all prop­ erly seated.
(15) Assemble front annulus gear and support if
necessary.
(16) Position thrust plate on front annulus gear
support (Fig. 80). Use liberal quantity of petroleum
jelly to hold plate in place.
(17) Install front planetary gear on intermediate
shaft and in driving shell (Fig. 81).
(18) Install front thrust washer on front planetary
gear (Fig. 81). Use enough petroleum jelly to hold
washer in place on gear and be sure washer tabs are seated.
Fig.
79 Installing Rear Thrust
Washer
On Front
Planetary Gear—42RH

Fig.
80 Installing Thrust
Plate
On Front
Annulus
Support—42RH

Fig.
81 Installing Front Planetary And
Annulus
Gears—42RH

21
- 254
TRANSMISSION OVERHAUL-42RH

• (19) Assemble front annulus gear and support. Be
sure support snap ring is seated. (20) Install front annulus thrust washer (Fig. 82).
Align flat on washer with flat on planetary hub. Also
be sure washer tab is facing forward.
Fig.
82 Installing Front
Annulus
Thrust

Washer-42RH
(21) Install front annulus snap ring (Fig. 83). Use
snap ring pliers to avoid distorting ring during in­
stallation. Also be sure ring is fully seated.
Fig.
83 Installing Front
Annulus Snap Ring—42RH

(22) Install planetary selective snap ring with snap
ring pliers (Fig. 84). Be sure ring is fully seated.
(23) Turn planetary geartain assembly over so
driving shell is facing workbench. Then support
geartrain on wood block positioned under forward
end of output shaft. This is necessary so geartrain
components will move forward for accurate end play check.
(24) Check planetary geartrain end play with
feeler gauge (Fig. 85). Gauge goes between shoulder
on intermediate shaft and end of rear annulus sup­
port.
SELECTIVE

Fig.
84 Installing Planetary Selective
Snap Ring-42RH
(25) 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.
85
Checking
Planetary
Geartrain
End

Play-42RH
FRONT
SERVO
AND
BAND OVERHAUL

FRONT
SERVO DISASSEMBLY
(FIG. 86) (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.

TRANSMISSION
OVERHAUL-42RH
21 - 255
FRONT BAND AND SERVO 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.
PISTON PISTON

ROD
ROD

SNAP
RING
SERVO

PISTON

ROD

GUIDE
PISTON

SEALS

PISTON
ROD

SEAL

PISTON

SPRING

SERVO
ROD
SNAP
GUIDE RING
SEAL J912M72

Fig.
86 Front
Servo
Components—42RH
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. 86).

REAR
SER¥0 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. 87). 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.

87).
(4) Open vise and remove wood block, piston plug,
cushion spring and servo piston.

SMALL
WOOD BLOCK

PISTON PLUG

SNAP
RING
SNAP

RING

PLIERS

J9121-174

Fig.
87 Removing/lnstailing
Servo
Piston
Piug
Snap
Ring—42RH

REAR SERVO INSPECTION Clean the servo components (Fig. 88) 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 pivot and
reaction pins. Minor pin scoring can be cleaned up
with crocus cloth. However, replace the pins if worn, severely scored, or cracked. Replace the pin O-rings.
Inspect the servo components. Replace the servo
and cushion springs if collapsed, distorted or broken.
SPRING
RETAINER
SERVO
SPRING

PISTON PLUG

CUSHION
SPRING SERVO
SNAP
RING

PISTON PLUG

SNAP
RING

SERVO

PISTON
J9121-173

Fig.
88 Rear
Servo
Components—42RH