1993 DODGE TRUCK Service Repair Manual

21
- 264
TRANSMISSION QVERHAUL-42RH
ADJUSTING

-
SCREW
AND
SWITCH

CONNECTOR
SEAL
J9321-226
Fig. ! *8 Serviceable Valve
Body

Components—42RH

CAUTION;
Many
of the
waives
and
plugs,
such
as

the
throttle
valve,
shuttle
valve plug,
1-2 shift
valve
and
1-2
governor plug,
are
made
of
coated alumi­ num
(Fig. 119).
Aluminum components
are
identi­
fied
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
un­

der
any
circumstances. This practice could damage
the special coating.

Inspect the valves and plugs for scratches, burrs,

nicks,
or scores. Minor surface scratches can be re­
moved with crocus cloth but do not round off the
edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The
edges prevent foreign matter from lodging between
the valves and plugs and the 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.

Check the two separator plates for distortion or.
damage of any kind. Inspect the upper housing,
lower housing,
3-4
accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and
transfer plate check balls as well. The check balls and ball seats must not be worn or damaged.
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 han­
dling.

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 SHUTTLE VALVE

COVER

SLEEVE

REGULATOR
VALVE THROTTLE

PRESSURE
PLUG
RETAINER VALVE

SPRING
2-3 SHIFT
VALVE GOVERNOR PLUG
LINE

PRESSURE

ADJUSTING-
SCREW
ADJUSTING

SCREW

BRACKET
PRESSURE

SWITCH REGULATOR* VALVE VALVE AND
AND

SPRING SPRING
SHUTTLE VALVE
PLUG
(ALUM.)

GOVERNOR
VALVE END PLATE
MANUAL LEVER DETENT BALL
AND
SPRING

J9221-21

Fig. 119 Upper Housing Components-42RH Valve Body (Alum. Indicates Aluminum Part)

21
- 266
TRANSMISSION
OWERHAUL-42RH

•
VALVE
BODY REASSEMBLY

CAUTION:
Do not
force
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. Over­

tightening
can
distort
the
housings
resulting
in
valve sticking,
cross
leakage and unsatisfactory op­

eration.
Tighten valve body
screws
to recom­ mended
torque
only.
Lower
Housing
Assembly
(Fig. 116)
(1) Lubricate valves, springs, and the housing
valve and plug bores with transmission fluid.
(2) Install 3-4 timing valve spring and valve in
lower housing.
(3) Install 3-4 shuttle valve in lower housing.
Press valve inward and install E-clip on end of valve
to secure it in housing. (4) Install 3-4 shuttle valve spring and throttle
plug in housing.
(5)
Install timing valve end plate. Tighten end
plate screws to 4 N«m (35 in. lbs.) torque.
(6) Install 3-4 shift valve and spring.
(7) Install converter clutch valve, spring and plug.
(8) Install converter clutch timing valve and
spring.

3-4
Accumulator
Assembly
(Fig. 117) (1) Lubricate accumulator piston, seals and hous­
ing piston bore with transmission fluid. (2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing. (4) Install end plate on housing.
Transfer Plate
Assembly
(1) Install rear clutch check ball in transfer plate
(Fig. 110). (2) Install filter screen in upper housing separator
plate (Fig. 109). (3) Align and position upper housing separator
plate on transfer plate (Fig. 109).
(4) Install brace plate (Fig. 108). Tighten brace at­
taching screws to 4 N«m (35 in. lbs.) torque. (5) Install remaing separator plate attaching
screws. Tighten screws to 4 Nrn (35 in. lbs.) torque.

Assembling
Upper And Lower
Housings
(1) Position upper housing so internal passages
and check ball seats are facing upward. Then install
check balls in housing (Fig. 111). Seven check balls are used. The single large check ball is approxi­
mately 8.7 mm (11/32 in.) diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 in.) in di­ ameter. (2) Position transfer plate assembly on upper hous­
ing (Fig. 120).
(3) Position lower housing separator plate on
transfer plate (Fig. 120).

TRANSFER
UPPER
PLATE
HOUSING
J932M59

Fig.
120
Lower
Housing
Separator
Plate
Installation
(4) Install lower housing on assembled transfer
plate and upper housing (Fig. 121).
(5) Install and start valve body screws by hand.
Then tighten screws evenly to 4
N*m
(35 in. lbs.) torque. Start at center and work out to sides when
tightening screws.

Fig.
121
Assembling
Valve
Body
Upper And
Lower
Housings—42
RH

Upper
Housing
Valve And
Plug
Installation
(Figs.
114, 115,

118)
(1) Lubricate valves, plugs, springs with Mopar
ATF Plus transmission fluid.
(2) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring. Insert assembly in
upper housing and install cover plate. Tighten cover
plate screws to 4
N*m
(35 in. lbs.) torqe.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install shift valve cover plate.

•

TRANSMISSION
0VERHAUL-42RH
21 - 267 (6) Install shuttle valve as follows:
(a) Insert plastic guides in shuttle valve second­
ary spring and install spring on end of valve. (b) Hold shuttle valve in place.
(c) Compress secondary spring and install E-clip
in groove at end of shuttle valve. (d) Verify that spring and E-clip are properly
seated before proceeding.
(7) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N*m (35 in. lbs.) torque.
(8) Install 1-2 and 2-3 valve governor plugs in
valve body.
(9) Install shuttle valve primary spring and throt­
tle plug. (10) Align and install governor plug cover. Tighten
cover screws to 4 N#rn (35 in. lbs.) torque.
(11) Install manual valve.
(12) Install throttle valve and spring.
(13) Install kickdown valve and detent.
(14) Install regulator valve. (15) Install switch valve.

Boost
Valve Tube Installation (1) Position valve body assembly so lower housing
is facing upward (Fig. 122).
(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Position tube behind tube brace (Fig. 122).
(4) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube into upper housing port (Fig. 122).
Seat both ends of tube once in position.
TUBE
BRACE
UPPER
LOWER
HOUSING PORT
J932M62

Fig.
122
Boost
Vaive
Tube Installation-42RH 3-4
Accumulator
Installation
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 123).
(2) Loosely attach accumulator housing with right-
side screw (Fig. 123). Install only one screw at this
time as accumulator must be free to pivot upward for ease of installation. (3) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(4) Swing accumulator housing upward over valve
springs and plug.
(5) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated (Fig. 124).

RIGHT-SIDE
SCREW

3-4
ACCUMULATOR
Fig.
123 Installing Converter
Clutch
And 3-4 Shift
Valve
Springs—42RH
CLUTCH ACCUMULATOR
VALVE PLUG
BOSS
J932M61

Fig.
124 Seating 3-4
Accumulator
On
Lower
Housing—42RH
(6) Attach solenoid case connector to 3-4 accumula­
tor with shoulder-type screw. Connector has small lo­ cating tang that fits in dimple at top of accumulator
housing (Fig. 125). Seat tang in dimple before tight­ ening connector screw.
(7) Install solenoid assembly and gasket. Tighten
solenoid attaching screws to 8 N*m (72 in. lbs.)
torque.

21
- 268
TRANSMISSION
OVERHAUL-42RH

SOLENOID

CASE
CONNECTOR

Fig. 125 Solenoid Connector Installation—42RH (8) Verify that solenoid wires are properly routed
(Fig. 126). Solenoid wires must be clear of rear
band lever, manual lever and
park
rod.
Fig, 126 Solenoid Wire Routing—42RH

Valve
Body
Final
Assembly
And
Adjustment
(1) Insert manual lever detent spring in upper
housing. (2) Position line pressure adjusting screw in ad­
justing screw bracket.
(3) Install spring on end of line pressure regulator
valve. (4) Install switch valve spring on tang at end of
adjusting screw bracket.
(5) Position adjusting screw bracket on valve body.
Align valve springs and press bracket into place. In­ stall short, upper bracket screws first and long bot­
tom screw last. Verify that valve springs and bracket _ . . _ +
Fig. 127 Manual And Throttle Lever

Alignment-42RH

VALVE
BODY CONTROL PRESSURE

ADJUSTMENTS
There are two control pressure adjustments on the
valve body which are, line pressure and throttle pres­
sure.

Line and throttle pressure work together as each
affects shift quality and timing. Both adjustments are properly aligned. Then tighten all three bracket
screws to 4 N*m (35 in. lbs.) torque.
(6) Install throttle lever in upper housing. Then in­
stall manual lever over throttle lever and start man­
ual lever into housing.
(7) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with Re­
tainer Tool 6583 (Fig. 93).
(8) Align manual lever with detent ball and man­
ual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove de­
tent ball retainer tool after lever is seated.
(9) Then Install manual lever seal, washer and
E-clip.
(10) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly.
(11) Verify that throttle lever is aligned with end
of kickdown valve stem and that manual lever arm
is engaged in manual valve (Fig. 127).
(12) Install boost valve, valve spring, retainer and
cover plate. Tighten cover plate screws to 4 N*m (35
in. lbs.) torque. (13) Obtain new fluid filter for valve body but do
not install filter at this time. (14) 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.

•

TRANSMISSION
OVERHAUL-42RH
21 - 269 must be performed properly and in the correct se­
quence. Line pressure is adjusted first and throttle
pressure is adjusted last.
Line
Pressure
Adjustment
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 128).
Distance should be 33.4 mm (1-5/16 inch).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting. The 33.4 mm (1-5/16 inch) setting is an approx­
imate 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.

Fig.
128
Line
Pressure
Adjustment

Throttle
Pressure
Adjustment Insert Gauge C-3763 between the throttle lever
cam and the kickdown valve stem (Fig. 129).
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.

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
Fig.
129
Throttie
Pressure
Adjustment
clean. Also make sure the tools and workbench area
used for assembly operations are equally clean.
Shop towels used for wiping off tools and hands
must be made from lint free material. Lint will stick
to transmission parts and could interfere with valve operation, or even restrict fluid passages.
Lubricate the transmission components with Mopar
transmission fluid during reassembly. Use petroleum
jelly, Door Eze, or Ru-Glyde on seals and O-rings to ease installation.
Petroleum jelly can also be used to hold thrust
washers, thrust plates and gaskets in position during assembly. However, do not use chassis grease, bear­
ing grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can eventually block or restrict fluid passages and inter­
fere with valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission
components and sub-assemblies are easily installed
by hand when properly aligned.
If a part seems extremely difficult to install, it is
either misaligned or incorrectly assembled. Also ver­
ify that thrust washers, thrust plates and seal rings are correctly positioned before assembly. These parts
can interfere with proper assembly if mispositioned (or "left out" by accident).
The planetary geartrain, front/rear clutch assem­
blies and oil pump are all much easier to install
when the transmission case is upright or as close to
this position as possible. Either tilt the case upward
with wood blocks, or cut a hole in the bench large enough for the output shaft. Then lower the shaft
through the hole and support the transmission case
directly on the bench.

TRANSMISSION ASSEMBLY PROCEDURE
(1) Install rear servo piston, spring and retainer
(Fig. 130). Install spring on top of servo piston and
install retainer on top of spring.
(2) Install front servo piston assembly, servo
spring and rod guide (Fig. 131).

21
- 271
TRANSMISSION
OWERHAUL-42RH

•

SERVO

PISTON PISTON

SPR
NG
SNAP

RING

PISTON
SEAL
RETAINER
J9121-343

Fig.
130 Rear
Servo
Components—42RH

PISTON
SEAL

RINGS
SERVO
PISTON

SNAP
RING
(4) Examine bolt holes in overrunning clutch cam.
Note that one hole is not threaded (Fig. 133). This
hole must align with blank area in clutch cam bolt
circle (Fig. 134). Mark hole location on clutch cam and blank area in case with grease pencil, paint
stripe, or scribe mark for assembly reference.
NON-THREADED
HOLE
OVERRUNNING CLUTCH
CAM
J9121-226

ROD

ROD
SPRING GUIDE
J9121-344

Fig.
131 Front
Servo
Components—42RH

(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap ring (Fig. 132).
SPRING

COMPRESSOR
TOOL

C-3422-B

ROD

QUIDE
SNAP
RING
J9121-136

Fig.
132
Compressing
Front/Rear
Servo
Springs
Fig.
133 Location Of Non-Threaded Hole In
Clutch

Cam-42RH

S>
OVERRUNNING CLUTCH
CAM

SEAT
IN
CASE 40N-THREADED
HOLE
IN
CLUTCH CAM ALIGNS

HERE
(BLANK AREA) OF SEAT
i
J9121-541

Fig.
134 Location Of
Blank
Area In
Clutch
Cam
Bolt
Circle-42RH
(5) Mark location of non-threaded hole in clutch
cam and blank area in bolt circle with grease pencil.
(6) Align and install overrunning clutch and cam
in case (Fig. 135). Be sure cam is correctly in­ stalled. Bolt holes in cam are slightly counter­sunk on one side. Be sure this side of cam faces
rearward (toward piston retainer).
(7) Verify that non-threaded hole in clutch cam is
properly aligned. Check alignment by threading a
bolt into each bolt hole. Adjust clutch cam position if necessary.
(8) Install and tighten overrunning clutch cam
bolts to 17 N«m (13 ft. lbs.) torque. Note that clutch cam bolts are shorter than piston retainer bolts.

•

Fig.
135 Overrunning
Clutch
Installation—42RH (9) Lubricate clutch cam rollers with transmission
fluid.
(10) Install rear band reaction pin (Fig. 136). Be
sure pin is fully seated in case.
Fig.
136 Installing Rear
Band
Reaction
Pin—42RH

(11) Install rear band in case (Fig. 137). Be sure
twin lugs on band are seated against reaction pin.
(12) Install low-reverse drum and check overrun­
ning clutch operation as follows:
(a) Lubricate overrunning clutch race (on drum
hub) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start race (on drum
hub) into overrunning clutch rollers. (d) Press drum rearward and turn it in clockwise
direction until drum seats in overrunning clutch (Fig. 138). (e) Turn drum back and forth. Drum should ro­
tate freely in clockwise direction and lock in
counterclockwise direction (as viewed from
front of case). (13) Install new gasket at rear of transmission

case.
Use petroleum jelly to hold gasket in place. Be
TRANSMISSION
0VERHAUL-42RH
21 - 271

Fig.
137 Rear
Band
Installation—42RH

Fig.
138 Installing
Low-Reverse
Drum—42RH
sure to align governor feed holes in gasket with feed
passages in case (Fig. 139). Also install gasket before overdrive piston retainer. Center hole in gasket is
smaller than retainer and cannot be installed over
retainer.
(14) Install overdrive piston retainer. Be sure gov­
ernor tube bores in retainer are aligned with gover­
nor feed passages in gasket and case (Fig. 140).
Install and tighten retainer bolts to 17 N#m (13 ft. lbs.) torque.
(15) Install snap ring that secures low-reverse
drum to hub of piston retainer (Fig. 141). (16) Install rear band lever and pivot pin (Fig.

142).
Align lever with pin bores in case and push
pivot pin into place.