1993 DODGE TRUCK Service Repair Manual

21
- 256
TRANSMISSION OVERHAUL-42RH

Replace the plug or piston if cracked, bent, or worn.
Discard the servo snap ring and spring retainer if
distorted or warped. If doubt exists about the condition of any servo
component, replace it. Do not reuse suspect parts.
ASSEMBLING REAR SERWO PISTON (1) Assemble piston plug, cushion spring and pis­
ton (Fig. 88). (2) Compress cushion spring in vise and install pis­
ton plug snap ring (Fig. 87).
(3) Install new seal on piston. Be sure seal lip is
toward servo bore (Fig. 89). (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.
89 installing Rear
Servo
Piston
Seal

VALVE
BODY
SERVICE
AND ADJUSTMENT
WALWE
BODY MAIN COMPONENT
DISASSEMBLY

CAUTION:
Do not
clamp
any
valve body compo­
nent
in a
vise. This
practice
can
damage
the
com­
ponent
resulting
in
unsatisfactory operation
after

assembly
and
installation. Remove valves,
plugs

and
springs
with
a
pencil magnet.
Do not use
pliers
to remove
any of the
valves, plugs
or
springs
and
do
not
force
any of the
components
out or into
place.
The
valves
and
valve body
housings
will
be

damaged
if
force
is
used.
Tag or
mark
the
valve body springs
for
reference
as
they
are
removed.
Do
not allow
them
to
become intermixed.

(1) Remove boost valve cover (Fig. 90).
(2) Remove boost valve retainer, valve spring and
boost valve (Fig. 91). (3) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 92).
(4) Remove E-clip that secures throttle lever in
manual lever (Fig. 93). (5) Lift and rotate manual lever far enough to
clear detent housing.
IK)
O °o O OOO

UPPER
HOUSING
J9321-126
Fig.
90
Boost
Valve
Cover
Location—42RH

BOOST VALVE
INSTALLED
LOCATION
SPRING BOOST AND VALVE BOOST
VALVE SPRING VALVE
RETAINER COVER

SCREWS

J9321-127

Fig.
91
Boost
Valve
Components
SPECIAL

TOOL
6583

DETENT BALL AND SPRING HOUSING
J9321
-121
Fig.
92
Securing
Detent
Ball
And
Spring

•

TRANSMISSION
0VERHAUL-42RH
21 - 257

THROTTLE
LEVER

AAANUAL
LEVER
E-CLIP
J9321-138

Fig. 93 Removing Throttle Lever
E-Clip

(6) Remove retaining tool and remove detent ball
and spring (Fig. 94). AAANUAL

LEVER

DETENT
HOUSING

DETENT
BALL.

AND
SPRING
J9321-139

Fig.
94 Detent Bali And Spring Removal (7) Remove washer at top of manual lever shaft.
Then lift manual lever and park rod assembly up­
ward and out of valve body (Fig. 95).
AAANUAL
LEVER AND
PARK ROD

ASSEMBLY

MANUAL LEVER
WASHER
J932M40

Fig.
95 Manual
Lever
Removal—42RH (8) Remove throttle lever from valve body housing
(Fig. 96).
THROTTLE

LEVER

J932M41

Fig.
96
Throttle
Lever
Removal—42RH (9) Remove park rod E-clip and separate rod from
manual lever (Fig. 97).
MANUAL
LEVER
PARK ROD
J9121-81

Fig.
97
Park
Rod Removal—42RH
(10) Remove screws attaching pressure adjusting
screw bracket to valve body and transfer plate. Hold
bracket firmly against spring tension while removing last screw.
(11) Remove adjusting screw bracket, line pressure
adjusting screw, pressure regulator spring and switch
valve spring (Fig. 98). Do not remove throttle
pressure adjusting screw from bracket and do
not disturb adjusting screw settings during re­
moval.
(12) Remove solenoid connector from 3-4 accumula­
tor housing (Fig. 99). Note that connector is at­
tached to housing with shoulder-type screw.
Keep this screw with accumulator housing to avoid losing it.
(13) Note routing of solenoid wires for assembly
reference (Fig. 100).
(14) Remove screws attaching solenoid assembly to
valve body lower housing and remove solenoid and connector assembly (Fig. 101).

21
- 258
TRANSMISSION 0VERHAUL-42RH

•

PRESSURE

REGULATOR
VALVE SPRING
ADJUSTING
SCREW

BRACKET

SWITCH VALVE

SPRING
LINE PRESSURE
ADJUSTING SCREW
J9121-512

Fig.
98 Adjusting
Screw
Bracket And
Spring

Removal—42RH

SOLENOID
CONNECTOR
3-4

ACCUMULATOR HOUSING

a=J932M43

Fig.
99
Solenoid
Connector
Position—42RH
SOLENOID
WIRES
(NOTE
WIRE

ROUTING)
s\^t%U^r
^^^^

Fig.
100
Solenoid
Wire
Routing—42RH
SOLENOID

ATTACHING
SCREWS
LOWER
HOUSING
SOLENOID
ASSEMBLY
J932M44

Fig.
101
Solenoid
Assembly
Removal—42RH (15) Remove 3-4 accumulator housing attaching
screws and remove housing from valve body (Fig.

102).

3-4

ACCUMULATOR- HOUSING HOUSING

ATTACHING
SCREWS

Fig.
102
Removing
3-4
Accumulator
Housing—42RH
(16) Remove following parts from valve body lower
housing: 3-4 shift valve and spring; pressure regula­
tor valve spring; clutch valve; clutch valve spring; and clutch valve plug (Fig. 103).
(17) Remove boost valve connecting tube (Fig.

104).
Disengage tube from upper housing port first.
Then rock opposite end of tube back and forth to
work it out of lower housing.

CAUTION:
Do not use
tools
to
loosen
or pry the

connecting
tube
out of the
valve body
housings.
Loosen
and
remove
the
tube
by
hand only.

(18) Turn valve body over so valve lower housing
is facing upward (Fig. 105). In this position, check
balls in upper housing will remain in place and not fall out when lower housing and transfer plate are
removed.

TRANSMISSION
0VERHAUL-42RH
21 - 259

LOWER

HOUSING
CLUTCH

VALVE
AND
SPRING
3-4

SHIFT

VALVE
AND

SPRING
PRESSURE

CLUTCH
REGULATOR
VALVE VALVE
PLUG
SPRING
J9321-146

Fig.
103
Clutch
Valve And 3-4 Shift Vaive
Locations—42
RH
BOOST

.VALVE
TUBE
LOWER

HOUSING

UPPER

HOUSING
DISENGAGE

THIS
END OF
TUBE
FIRST
J9321-147

Fig.
104
Boost
Valve Tube Removal—42RH (19) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
105).
Note position of boost valve tube brace for
assembly reference.
(20) Remove lower housing and overdrive separa­
tor plate from transfer plate (Fig. 106).
(21) Remove transfer plate from upper housing
(Fig. 107). (22) Turn transfer plate over so upper housing sep­
arator plate is facing upward (Fig. 108).
(23) Remove brace plate from lower housing sepa­
rator plate and transfer plate (Fig. 108).
(24) Remove upper housing separator plate from
transfer plate (Fig. 109). Note position of filter in separator plate for assembly reference.
LOWER

HOUSING
VALVE

BODY

SCREWS
(13)
S
^ c
TUBE
BRACE
J9321-148

Fig.
105 Valve
Body
Screw
And Tube
Brace
Location—42RH

OVERDRIVE

SEPARATOR
PLATE
TRANSFER

PLATE
AND
UPPER

HOUSING

LOWER

HOUSING
J9321-149

Fig.
106
Lower
Housing
Removal—42RH
UPPER

HOUSING

TRANSFER

PLATE

J932M52

Fig.
107
Removing
Transfer
Plate
From Upper
Housing—42RH

(25) Remove rear clutch check ball from transfer
plate. Note check ball location for assembly
ref­
erence before removing it (Fig. 110).

21
- 260

TRANSMISSION
0VERHAUL-42RH

•

BRACE

J9321-150
SEPARATOR
TRANSFER
PLATE PLATE
Fig.
108 Brace
Plate
Removal—42RH

TRANSFER
PLATE
UPPER

HOUSING

'SEPARATOR
PLATE

FILTER

SCREEN

BRACE
J932M51

Fig.
109 Upper
Housing
Separator
Plate
Removal—42RH

TRANSFER
PLATE

REAR

CLUTCH
CHECK

BALL

Fig.
110 Rear
Clutch
Check
Ball
Location—42RH
VALVE
BODY UPPER HOUSING

DISASSEMBLY
(1) Note location of check balls in valve body upper
housing (Fig. 111). Then remove one large and six
smaller diameter check balls with magnet (total of 7
check balls are used).
SMALL

DIAMETER
CHECK

BALLS
(6)

LARGE
DIAMETER
CHECK

BALL
(1)
J9321-154

Fig.
111
Valve
Body Check
Ball
Locations—42RH (2) Remove E-clip that secure shuttle valve second­
ary spring on valve stem (Fig. 112).
E-CLIP

SECONDARY

SHUTTLE

VALVE

J9121-179

Fig.
112 Shuttle
Valve
E-Clip And
Secondary
Spring
Location—42RH
(3) Remove governor plug and shuttle valve covers
(Fig. 113). (4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 113).
(5) Remove boost valve retainer, spring and valve
if not previously removed.

•

TRANSMISSION
OVERHAUL42RH
21 - 261 -156
Fig. 113 Shuttle And
Boost
Valve Components—42RH
(6) Turn upper housing over and remove switch (8) Remove throttle plug and 1-2 and 2-3 governor
valve, regulator valve and spring, and manual valve plugs (Fig. 114). Also remove shuttle valve primary (Fig. 114). spring if not removed in prior step.
(7) Remove kickdown detent, kickdown valve, and
throttle valve and spring (Fig. 114). Fig. 114 Control Valve Locations—42RH Upper Housing

21
- 212
TRANSMISSION OWERHAUL-42RH

UPPER

HOUSING
1-2

SHIFT

CONTROL VALVE
AND SPRING
2-3

SHIFT

VALVE
AND SPRING
THROTTLE

PRESSURE
SPRING
AND
PLUG COVER
PLUG

SLEEVE

LINE

PRESSURE
PLUG

PRESSURE
PLUG

COVER
J9321-243

Fig.
115 Shift
Waives
And
Pressure
Plugs—42RH
Upper
Housing
(9) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 115).
(10) Remove limit valve housing. Then remove re­
tainer, spring, limit valve, and 2-3 throttle plug from limit valve housing (Fig. 115).
(11) Remove 1-2 shift control valve and spring
(Fig. 115). (12) Remove 1-2 shift valve and spring (Fig. 115).
(13) Remove 2-3 shift valve and spring from valve
body (Fig. 115).
(14) Remove pressure plug cover (Fig. 115). (15) Remove line pressure plug, sleeve, throttle
pressure plug and spring (Fig. 115).
VALWE BODY LOWER HOUSING
DISASSEMBLY (FIG. 116) (1) Remove timing valve cover.
(2) Remove 3-4 timing valve and spring.
(3) Remove 3-4 shuttle valve E-clip and remove
shuttle valve spring and plug.
(4) Remove 3-4 shift valve and spring.
(5) Remove converter clutch valve, spring and
plug.
(6) Remove converter clutch timing valve, retainer
and valve spring.
3-4
ACCUMULATOR HOUSING DISASSEMBLY
(FIG. 117)
(1) Remove end plate from housing.
(2) Remove piston spring. (3) Remove piston. Remove and discard piston

seals.

VALWE
10DY
CLEANING AND INSPECTION
The only serviceable valve body components are
(Fig. 118):"
• solenoid and connector assembly
• solenoid gasket and connector screw
• switch valve and spring • pressure adjusting screw and bracket
• throttle valve lever • manual lever and shaft seal
• throttle lever shaft seal, washer, and E-clip
• fluid filter and screws
• detent ball
• valve body screws The park rod and park rod E-clip are also service­

able.
Refer to the park lock components and over­
drive case information in the parts catalogue. The
remaining valve body components are serviced only as part of a complete valve body assembly. Clean the valve body components with a standard
parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution.

4

TRANSMISSION
QVERHAUL-42RH
21 - 263

Fig.
116 Shift Valves And 3-4 ACCUMULATOR
^ HOUSING
PLATE
J9121-277
Fig.
117 3-4
Accumulator
Housing
Components—42
RH

Dry the parts with compressed air. Make sure all
passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off
wings—42RH
Lower
Housing

valve body components. Lint from these materi­als 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
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 a sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur­

face.
If distortion is severe or any surfaces are
heavily scored, the valve body will have to be re­
placed.