1993 DODGE TRUCK Service Repair Manual

21
- 288
TRANSMISSION OVERHAUL-48RH
Fig.
44
Positioning
Puller
Plate
On
Clutch
Cam

Fig.
45 Installing Overrunning
Clutch
Cam—46RH
stall and seat spring in retainer first. Then insert
roller between spring and retainer stop as shown (Fig. 46). Verify that each roller and spring are fully
seated before proceeding.
(3) Install and seat clutch assembly in cam (Fig.

47).
The retainer is a one-way fit in the cam. The
flanged side of the retainer should be facing out­ ward. The retainer and rollers will slip easily
into the cam when properly positioned.
(4) Install low-reverse drum. Tilt drum slightly
and carefully engage clutch race (on drum hub) in
overrunning clutch rollers. Raise drum to level posi­
tion. Then rotate the drum in clockwise direction un­
til fully seated. •

Fig.
47 Overrunning
Clutch
Seated In Cam (5) Check overrunning clutch operation. Low-re­
verse drum should rotate freely in clockwise direc­
tion and lock in counterclockwise direction.
(6) Align and reinstall overdrive piston retainer.
Tighten retainer bolts to 11 N*m (95 in. lbs.) torque.

ACCUMULATOR OVERHAUL
Inspect the accumulator piston and seal rings (Fig.

48).
Replace the seal rings if worn or cut. Replace the
piston if chipped or cracked. Check condition of the accumulator inner and outer
springs (Fig. 48). Replace the springs if the coils are
cracked, distorted or collapsed.

TRANSMISSION
0VERHAUL-46RH
21 - 289

ACCUMULATOR PISTON
INNER

SPRING
OUTER

SPRING

SEAL

RINGS
J9121-230

Fig.
48
Accumulator
Components—46RH

FRONT
SERVO
AND BAND OVERHAUL
Clean the servo piston components with solvent
and dry them with compressed air. Wipe the band
clean with lint free shop towels. Replace the front band if distorted, lining is
burned, flaking off, or worn to the point where the grooves in the lining material are no longer visible. 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. Check the servo piston bore for wear. If the bore is
severely scored, or damaged, it will be necessary to
replace the case. Replace any servo component if in doubt about its
condition. Do not reuse suspect parts.

FRONT
SERVO PISTON OVERHAUL
(FIG. 49) (1) Remove seal ring from rod guide. (2) Remove small snap ring from servo piston rod.
Then remove piston rod, spring and washer from pis­ ton.
(3) Remove and discard servo component O-ring
and seal rings.
(4) Lubricate new O-ring and seal rings with pe­
troleum jelly and install them on piston, guide and rod.
(5) Install rod in piston. Install spring and washer
on rod. Compress spring and install snap ring.
(6) Set servo components aside for installation dur­
ing transmission reassembly.

REAR
SERVO AND BAND OVERHAUL
Clean the servo components with solvent and dry
them with compressed air. Inspect the servo compo­
nents.
Replace the spring if collapsed, distorted or
broken. Replace the plug and piston if cracked, bent, or worn. Discard the servo snap ring if distorted or
warped. Check rear band condition. Replace the band if dis­
torted, the lining is burned or flaking off, or the lin­ ing is worn (grooves no longer visible at any point on
PISTON RINGS
(2)

SERVO
PISTON O" RING PISTON
ROD:

•
SPRING

<
WASHER

.SNAP
RING
PISTON
ROD
GUIDE
PISTON
ROD (A-727
ONLY)'

SERVO
SPRING-
SEAL
RING.
SNAP
RING-
RH307

Fig.
49 Front
Servo
Components—46RH
the lining material). If doubt exists about the condi­
tion of any servo component, replace it. Do not reuse
suspect parts.

REAR
SERVO PISTON OVERHAUL
(FIG. 50) (1) Remove small snap ring and remove plug and
spring from servo piston. (2) Remove and discard servo piston seal ring.
(3) Lubricate piston and guide seals with petro­
leum jelly. Lubricate other servo parts with Mopar
ATF Plus transmission fluid.
(4) Install new seal ring on servo piston.
(5) Assemble piston, plug, spring and snap ring.
(6) Lubricate piston seal lip with petroleum jelly.
(7) Set servo components aside for assembly instal­
lation.

SNAP
RING PISTON

SEAL
PISTON
PLUG
SPRING

RETAINER
SNAP
RING

PISTON CUSHION

SPRING
PISTON

SPRING
J9121-64

Fig.
50 Rear
Servo
Components—46RH

OIL PUMP AND REACTION SHAFT SUPPORT

OVERHAUL

PUMP
AND
SUPPORT DISASSEMBLY
(1) Mark position of support in oil pump body for
assembly alignment reference. Use scriber or paint to
make alignment marks.
(2) Place pump body on two wood blocks. (3) Remove reaction shaft support bolts and sepa­
rate support from pump body (Fig. 51). (4) Remove pump inner and outer gears (Fig. 52).
(5) Remove O-ring seal from pump body (Fig. 53).
Discard seal after removal.

21 - 290
TRANSMISSION OVERHAUL-46RH
•

REACTION SHAFT
SUPPORT GEAR
BORE

J932M76

Fig.
51 Reaction Shaft
Support
Removal—46RH
(6) Remove oil pump seal with Remover Tool

C-3981.
Discard seal after removal.
INSPECTING PUMP AND
SUPPORT
Clean pump and support components with solvent
and dry them with compressed air.
Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, severely
worn, or no longer hooked together.
PUMP BODY INNER
GEAR OUTER
GEAR
J932M77

Fig.
52
Pump
Gear Removal—46RH
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.
Fig.
53 Oil
Pump
And Reaction Shaft
Components—46RH

+

Fig.
55
Checking
Pump
Gear End Clearance

OIL
PUMP
BUSHING
REPLACEMENT
(FIG. 57} (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.
TRANSMISSION
0VERHAUL-46RH
21 - 291
J8921-388

Fig.
56
Checking
Pump
Gear
Side
Clearances
(3) Assemble Tool Handle C-4171 and Bushing In­
staller SP-5118. (4) Place bushing on installer tool and start bush­
ing into shaft.
(5) Tap bushing into place until Installer Tool SP-
5118 bottoms in pump cavity. 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. 58).
Check the pump vent (Fig. 54). The vent must be
secure. Replace the pump body if the vent is cracked,
broken, or loose.
Inspect the pump bushing (Fig. 54). Then check the
reaction shaft support bushing. Replace either bush­ ing only if heavily worn, scored or damaged. It is not
necessary to replace the bushings unless they are ac­
tually damaged.
Install the gears in the pump body and measure
end clearance with a feeler gauge and straightedge (Fig. 55). Clearance should be 0.89 to 1.90 mm (0.0035 to 0.0075 in.).
Measure side clearances with feeler gauge (Fig.

56).
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.).

PUMP

21
- 292
TRANSMISSION
OVERHAUL-46RH

•

SPECIAL
TOOL

C-4171
BUSHING
REMOVAL
PUMP HOUSING

SPECIAL
TOOL

C-4171
SPECIAL
TOOL

SP-3550

BUSHING

SPECIAL
TOOL

SP-5118
J9221-244

Fig. 57 Replacing Oil Pump Bushing
mm
Fig. 58 Staking-Debum'ng Oil Pump Bushing
REPLACING
REACTION SHAFT SUPPORT

BUSHING
(FIG. 59)
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushing Remover
SP-5301.
(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. Then slide new bushing onto installer tool. (7) Start bushing in shaft. Tap bushing into shaft
until installer tool bottoms against support flange. (8) Clean reaction shaft support thoroughly after
bushing replacement (to remove any chips).
SPECIAL

TOOL

SP-1191
SPECIAL

TOOL

C-4171

SPECIAL
TOOL

SP-5302

BUSHING BUSHING

X
REACTION SHAFT
BUSHING
REMOVAL BUSHING
INSTALLATION
J9221-245

Fig. 59 Reaction Shaft Bushing Replacement—46RH

ASSEMBLING
OIL
PUMP
AND
REACTION SHAFT SUPPORT

(1) Lubricate pump gears with transmission fluid
and install them in pump body.
(2) Install thrust washer on reaction shaft support

hub.
Lubricate washer with petroleum jelly or trans­ mission fluid before installation.
(3) If reaction shaft seal rings are being replaced,
install new seal rings on support hub. Lubricate seal
rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are
securely hooked together.

CAUTION:
The
reaction shaft support seal
rings
will
break
if
overspread,
or
twisted.
If new
rings
are be­

ing
installed,
spread them only enough
for
installa­
tion.
Also
be
very sure
the
ring ends
are
securely
hooked
together
after
installation. Otherwise,
the

rings
will
either
prevent
pump
installation,
or break

during installation.

(4) Align and install reaction shaft support on
pump body.
(5)
Install bolts attaching reaction shaft support to
pump. Tighten bolts to 20 N»m (175 in. lbs.) torque. (6) Install new pump seal with Seal Installer
C-3860-A (Fig. 60). Use hammer or mallet to tap seal
into place.
(7) Install new O-ring on pump body. Lubricate oil
seal and O-ring with petroleum jelly.

TRANSMISSION
0VERHAUL-46RH
21 - 293
(4) Remove clutch piston springs. Note number
and position of piston springs for assembly
ref­

erence. (5) Remove clutch piston from retainer with a
twisting motion. (6) Remove and discard clutch piston inner and
outer seals.

FRONT CLUTCH 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 and reaction
plate 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. Check the clutch piston check ball. The ball should
be securely in place. Replace the piston if the ball is missing, or seized in place.
INNER
CLUTCH CLUTCH PISTON CLUTCH CLUTCH
Fig.
61
46RH
Front
Clutch
Components
(3-Disc
Clutch
Shown)

SPECIAL

TOOL

C-3860-A

PUMP

SEAL
PUMP

BODY

J932M79

Fig.
60 Oil
Pump Seal
Installation—46RH (8) Set pump assembly aside for installation dur­
ing transmission assembly.

FRONT
CLUTCH
OVERHAUL

FRONT CLUTCH
DISASSEMBLY
(1) Remove waved snap ring and remove reaction
plate, clutch plates and clutch discs (Fig. 61). Note
number of plates and discs in clutch pack for as­ sembly reference. Some models use 3 discs,
while some may have 4 discs.
(2) Compress clutch piston retainer and piston
springs with Compressor Tool C-3863-A (Fig. 62).
(3) Remove retainer snap ring and remove com­
pressor tool.

21
- 294
TRANSMISSION
OVERHAUL-46RH

SPECIAL TOOL
C-3863-A

RH290
Fig.
62
Removing
Front
Clutch
Spring
Retainer
Snap Ring FRONT
CLUTCH
RETAINER
BUSHING
REPLACEMENT (FIG. 63)
(1) Assemble Tool Handle C-4171 and Bushing Re­
mover SP-3629.
(2) Insert remover tool in bushing and drive bush­
ing straight out of clutch retainer.
(3) Mount Bushing Installer SP-5511 on tool han­

dle.
(4) Slide new bushing onto installer tool and start
bushing into retainer.
(5) Tap new bushing into place until installer tool
bottoms against clutch retainer.
(6) Remove installer tools and clean retainer thor­
oughly.
ASSEMBLING
FRONT
CLUTCH (1) Soak clutch discs in transmission fluid. Lubri­
cate remaining clutch components with transmission
fluid. Retainer bushing can be lubricated with petro­
leum jelly if desired.
(2) Install new inner and outer seals on clutch pis­
ton. Be sure seal lips face interior of retainer. (3) Lubricate new inner and outer piston seals
with Ru-Glyde, or Door Eze.
(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 and position clutch piston springs as
shown in Figure 64.
(6) Install spring retainer on top of piston springs. (7) Compress spring retainer and piston springs
with Compressor Tool C-3863-A.
SPECIAL

TOOL-

C-4171

FRONT CLUTCH
RETAINER
vsvv

n

HI
BUSHING

HI

REMOVAL
SPECIAL

TOOL

SP-3629
SPECIAL

TOOL

C-4171
SPECIAL

TOOL

SP-5511
J9221-247

Fig.
63 Front
Clutch
Retainer
Bushing

Replacement—46RH

9
SPRING CLUTCH

11
SPRING CLUTCH
13 SPRING CLUTCH
J9221-260

Fig.
64 Front
Clutch
Spring
Location
(8) Install spring retainer snap ring and remove
compressor tool.
(9) Install clutch plates and discs. Install steel
plate followed by clutch disc until all plates and discs

•

TRANSMISSION
OVERHAUL-46RH
21 - 295 are installed. Install same number of discs and
plates as removed during disassembly. Some
models require 3 plates and discs. Others re­ quire 4 plates and discs.
(10) Install reaction plate and waved snap ring.
(11) Check clutch pack clearance with feeler gauge
as follows (Fig. 65):
• On 3 disc clutch, clearance between waved spring
and pressure plate should 1.78 - 3.28 mm (0.070 -
0.129 in.).
• On 4 disc clutch, clearance 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, clutch

discs,
snap ring and pressure plate will have to
be changed. Clutch pack waved snap ring is not select fit.

FEELER
GAUGE
RH288

Fig.
65
Measuring
Front
Clutch
Pack
Clearance

REAR
CLUTCH OVERHAUL

REAR
CLUTCH DISASSEMBLY
(FIG. 66) (1) Remove clutch pack select fit snap ring.
(2) Remove reaction plate and remove clutch plates
and discs.
(3) Remove pressure plate, wave spring, spacer
ring and piston spring from clutch retainer.
(4) Remove clutch piston from piston retainer with
a twisting motion. (5) Remove input shaft thrust washer, if washer
remained in piston retainer hub during removal.
(6) Remove seals from clutch piston. Discard seals
after removal.
REAR
CLUTCH INSPECTION

Clean the clutch components with solvent and dry
them with compressed air. Check condition of the input shaft seal rings. It is
not necessary to remove or replace rings unless they
are broken, cracked, or no longer securely hooked to­ gether.
Inspect the input shaft splines and machined sur­

faces.
Very minor nicks or scratches can be smoothed off with crocus cloth, replace the shaft if the splines
are damaged, or any of the machined surfaces are se­
verely scored.
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.
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

hub.
Replace the seal rings only if severely worn, cracked, or if they can no longer be hooked together.

INPUT SHAFT REPLACEMENT
If the input shaft must be replaced, first remove
the retaining ring that secures the shaft in the pis­
ton retainer hub. Then press the old shaft out of the retainer with a shop press.
Lubricate the splines of the new shaft with petro­
leum jelly or ATF Plus. Then align the shaft in the
piston retainer and carefully press it into place. Do not allow the shaft to become cocked during installa­
tion. The retainer can be cracked if misalignment oc­
curs.

Install the shaft retaining ring after pressing the

.
shaft into place. Be sure the ring is fully seated be­ fore proceeding with clutch assembly.