1993 DODGE TRUCK Service Repair Manual

21
- 296
TRANSMISSION OVERHAUL-46RH
Fig.
66 Rear
Clutch
REAR
CLUTCH
ASSEMBLY

(1) Soak clutch discs in transmission fluid. Lubri­
cate remaining clutch components with transmission
fluid. Clutch retainer bushing can be lubricated with
petroleum jelly if desired. (2) Install new seals on clutch piston. Lubricate
piston seals with Ru-Glyde or petroleum jelly to ease installation. Be sure seal lips face input shaft.
(3) Install clutch piston in piston retainer. Use
twisting motion to seat piston in retainer. Do not
push piston straight in. This could distort seals
causing leakage and clutch slip.
(4) Assemble piston retainer and clutch retainer.
(5) Support clutch retainer with wood blocks, or in­
sert input shaft through predrilled, appropriate di­ ameter hole in workbench. Clutch pack components
are easier to install if both retainers are properly
supported.
(6) Install piston spring in clutch retainer. Con­
cave side of spring faces upward and away from
clutch piston. Convex side faces downward toward
piston.
(7) Install spacer ring on top of piston spring.
(8) Install wave spring on top of spacer ring. Then
seat wave spring in retainer groove. If wave spring will not seat properly, spacer ring has probably shifted over and into wave spring groove in re­
tainer. Use small screwdriver to realign spacer ring if necessary.
(9) Install inner pressure plate in clutch retainer. (10) Install first clutch disc followed by steel plate
until all discs and plates are installed.
(11) Install reaction plate on top of last clutch disc.
Components—46RH

(12) Install selective snap ring to secure clutch
pack in retainer. (13) Install new seal rings on input shaft if neces­
sary (Fig. 67). Be very sure ring ends are all securely
hooked together before proceeding.

Fig.
67 Input Shaft
Seal
Ring
Locations

(14) Check clutch pack clearance with feeler gauge
(Fig. 68). Clearance should be 0.63 to 1.14 mm (0.025
to 0.045 in.).
(15) If clutch pack clearance is incorrect, clutch
pack snap ring, reaction plate, or clutch pack may
have to be replaced.
(16) Install thrust washer on piston retainer hub
(Fig. 66). Use petroleum jelly to hold thrust washer
in place.

•
J9321-167

Fig.
68 Measuring Rear Clutch Pack Clearance

PLANETARY
GEARTRAIN
OVERHAUL
PLANETARY
GEARTRAIN
DISASSEMBLY

(1) Remove planetary snap ring from intermediate
shaft (Fig. 69). Retain snap ring if in good condition.
It is reusable.
Fig.
69
Removing
Planetary
Snap
Ring—46RH

(2) Remove front planetary gear and front annulus
gear as assembly (Fig. 70). (3) Remove front planetary gear and thrust washer
from front annulus gear (Fig. 71). Note thrust
washer position for assembly reference. (4) Remove tabbed thrust washer from driving
shell (Fig. 72). Note washer position for assembly
ref­

erence.
(5) Remove sun gear and driving shell as assembly
(Fig. 73). (6) Remove tabbed thrust washer from rear plane­
tary gear (Fig. 74). Note washer position on gear for
assembly reference.
(7) Remove rear planetary gear and rear annulus
gear from intermediate shaft (Fig. 75).
(8) Remove thrust plate from rear annulus gear
(Fig. 76).
TRANSMISSION
0VERHAUL-46RH
21 - 297

Fig.
71
Disassembling
Front Planetary And
Annulus
Gears—46RH
Intermediate
Shaft
And
Geartrain
Inspection

Clean the intermediate shaft and planetary compo­
nents (Fig. 77) in parts cleaning solvent and dry
them with compressed air.
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.

21
- 298
TRANSMISSION
0¥IRHAUL-48RH

•

Fig.
72 Driving Shell Thrust Washer Removal—46RH
INTERMEDIATE SHAFT
Fig.
73 Sun Gear And Driving Shell Assembly
Removal—46RH

SUN
REAR

SHELL
J932M72

Fig.
74 Rear Planetary Thrust
Washer
Removal—46RH
Inspect the machined surfaces of the intermediate
shaft. Be sure the oil passages are open and clear.
Replace the shaft if scored, pitted, or damaged.
INTERMEDIATE REAR REAR
SHAFT ANNULUS PLANETARY

J932M73

Fig.
75 Rear Planetary And Annulus Gear Removal—46RH

REAR
J9321-174

Fig.
76 Rear Annulus Thrust Plate Removal—46RH
Inspect the sun gear and driving shell (Fig. 77). If
either component is worn or damaged, remove the sun gear rear retaining ring and separate the sun
gear and thrust plate from the driving shell. Then
replace the necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as an assembly 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.
PLANETARY GEARTRAIN ASSEMBLY AND
ADJUSTMENT
(1) Lubricate sun gear and planetary gears with
transmission fluid during assembly. Use petroleum
jelly 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 (Fig.

•

TRANSMISSION
QVERHAUL-46RH
21 - 299

Fig.
77 Planetary
Geartrain
Components—46
RH 78).
Install rear snap ring to secure sun gear and
thrust plate in driving shell. J932M75

Fig.
78 Sun Gear Installation—46RH (3) Install rear annulus gear on intermediate shaft
(Fig. 79).
(4) Install thrust plate in annulus gear (Fig. 80).
Be sure plate is seated on shaft splines and against gear.
(5) Install rear planetary gear in rear annulus
gear (Fig. 81). Be sure planetary carrier is seated
against annulus gear.
(6) Install tabbed thrust washer on front face of
rear planetary gear (Fig. 82). Seat washer tabs in
matching slots in face of gear carrier. Use extra pe­
troleum jelly to hold washer in place if desired.
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
Fig.
79 Installing Rear
Annulus
Gear On

Intermediate
Shaft—46RH (8) Install sun gear and driving shell on output
shaft (Fig. 83). Seat shell against rear planetary
gear. Verify that thrust washer on planetary gear
was not displaced during installation.
(9) Install tabbed thrust washer in driving shell
(Fig. 84). 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. 85). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
(11) Install front annulus gear over and onto front
planetary gear (Fig. 86). Be sure gears are fully
meshed and seated.

21
• 300
TRANSMISSION
OVERHAUL-48RH

•

OUTPUT SHAFT DRIVING

SHELL

THRUST PLATE

J9121-69

Fig.
80 installing Rear
Annulus
Thrust Plate—46RH REAR

ANNULUS

GEAR
REAR

PLANETARY
GEAR
SUN
GEAR
OUTPUT
SHAFT

J9121-72

Fig.
83 installing Sun Gear And Driving
Shell—46RH
TAB

SLOTS
(3)
DRIVING

SHELL
REAR

PLANETARY
GEAR

J9121-70

Fig.
81 Installing Rear Planetary Gear—46RH
REAR

PLANETARY
GEAR
TABBED

THRUST
_

WASHER
^121-71
Fig.
82 Installing Rear Planetary Thrust

Washer-46RH

(12) Install front planetary and annulus gear as­
sembly (Fig. 87). Hold gears together and slide them
TABBED

THRUST

WASHER

J9121-73

Fig.
84 Installing Driving
Shell
Thrust
Washer-46RH
onto shaft. Be sure planetary pinions are seated on
sun gear and that planetary carrier is seated on out­
put shaft.
(13) Place geartrain in upright position. Rotate
gears to be sure all components are seated and prop­
erly assembled. Snap ring groove at forward end of
output shaft will be completely exposed when compo­
nents are assembled correctly.
(14) Install planetary snap ring in groove at end of
output shaft (Fig. 88). (15) Turn planetary geartrain over. Position wood
block under front end of output shaft and support
geartrain on shaft. Be sure all geartrain parts have
moved forward against planetary snap ring. This is important for accurate end play check.

•

TRANSMISSION
0WERHAUL-4SRH
21 - 301

Fig.
85 Installing Thrust
Washer
On Front Planetary
Gear-46RH

Fig.
86
Assembling
Front Planetary And
Annulus
Gears—46RH
(16) Check planetary geartrain end play with
feeler gauge (Fig. 89). Insert gauge between rear an­
nulus gear and shoulder on output shaft as shown.
End play should be 0.15 to 1.22 mm (0.006 to 0.048

in.).

(17) If end play is incorrect, install thinner/thicker
planetary snap ring as needed.
Fig.
87 Installing Front Planetary And
Annulus
Gear

Assembly—46RH

Fig.
88 Installing Planetary
Snap
Ring—46RH

21
- 302
TRANSMISSION
OVERHAUL-46RH

Fig.
89
Checking
Planetary
Geartrain
End
Play

VALVE
BODY
SERVICE
AND
ADJUSTMENT
VALVE BODY MAIN COMPONENT

DISASSEMBLY

CAUTION:
Do not
clamp
any
valve
body
component
in
a
vise.
This
practice
can
damage
the
component

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
refer­

ence
as
they
are
removed.
Do not
allow
them
to be­

come
intermixed.

(1) Remove boost valve cover
(Fig. 90).

(2) Remove boost valve retainer, valve spring
and

boost valve
(Fig. 91).
HOUSING
J932M26
•

Fig.
91
Boost
Valve
Components—46RH

DETENT
BALL AND
SPRING
HOUSING
J9321-121
Fig.
92
Securing
Detent
Ball
And
Spring
(4) Remove E-clip that secures throttle lever
in

manual lever
(Fig. 93).
J932M38

Fig.
93
Removing
Throttle
Lever
E-Clip-46RH (5) Lift
and
rotate manual lever
far
enough
to

clear detent housing.
Fig.
90
Boost
Valve
Cover
Location—46RH
(3) Secure detent ball
and
spring with Retainer
Tool 6583
(Fig. 92).

TRANSMISSION
0VERHAUL-46RH
21 - 303
(6) Remove retaining tool and remove detent ball
and spring (Fig. 94).
MANUAL

LEVER

DETENT

HOUSING

DETENT
BALL.

AND

SPRING
J9321-139

Fig.
94 Detent
Ball
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).
MANUAL

LEVER
AND

PARK ROD

ASSEMBLY
MANUAL

LEVER
WASHER

J9321-140
Fig.
95 Manual
Lever
Removal—46RH
(8) Remove throttle lever from valve body housing
(Fig. 96).

THROTTLE
LEVER

J932M41

Fig.
96
Throttle
Lever
Removal—46RH (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—46RH
(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.
PRESSURE

REGULATOR

VALVE SPRING

SWITCH
VALVE

SPRING
LINE
PRESSURE

ADJUSTING
SCREW
ADJUSTING

SCREW

BRACKET
mm

J9121-512
Fig.
98 Adjusting
Screw
Bracket And
Spring

Removal—46RH
(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).