1993 DODGE TRUCK transmission fluid

•

NP241 TRANSFER
CASE
21 - 313
LOCK OIL RING SEAL

ADAPTER

(OVERDRIVE
ONLY)
SPEEDOMETER

PINION
GEAR

ADAPTER
O-RING

SPEEDOMETER
ADAPTER

RETAINER
DISTANCE
SENSOR
J9021-99

Fig.
4 Speedometer
Components

(4) Check vehicle speed sensor mounting area in
pinion adapter. If transmission fluid is found in this area, adapter oil seal is leaking and will have to be
replaced.
(5) Remove bolt and retainer securing pinion gear
adapter to extension housing.

(6)
Carefully work adapter and gear out of hous­
ing. (7) Remove and discard adapter O-ring (Fig. 4).

SPEEDOMETER ADAPTER
OIL
SEAL
REPLACEMENT
Remove adapter oil seal if necessary. Start new
seal in adapter by hand. Then press seal into adapter
with Installer Tool C-4004 until tool bottoms (Fig. 5).
ADAPTER

LOCK
RING

TOOL
(3) Count number of teeth on pinion gear before
installing gear in adapter.
(4) Note range numbers on adapter face (Fig. 6).
These numbers correspond to number of teeth on pin­ ion. (5) Install adapter in housing.

(6)
Rotate adapter until required range numbers
are at six o-clock position (Fig. 6). Be sure adapter
range numbers correspond to number of teeth on pin­ ion. (7) Seat adapter in housing.
(8) Install adapter retainer. Tighten retainer bolt
to 11 N-m (100 in. lbs.) torque.
(9) Install vehicle speed sensor. Tighten sensor
coupling nut to 17 N-m (150 in. lbs.) torque and in­
stall sensor wires.
(10) Check and correct transfer case lubricant level
if necessary.
(11) Install skid plate and crossmember if re­
moved. (12) Lower vehicle.
ADAPTER

O'CLOCK
POSITION

Fig.
6 Indexing Speedometer Adapter
RH75
OIL
SEAL

RH263

Fig.
5
Replacing
Speedometer Adapter
Seal

ADAPTER/SENSOR
INSTALLATION
CAUTION:
Before installing
the
pinion arid adapter

assembly
make sure
the
adapter flange
and its
mounting area
in
transfer case
are
perfectly clean. Dirt
or
sand
will
cause misalignment resulting
in

speedometer pinion gear damage.

(1) Thoroughly clean adapter flange and adapter
mounting surface in extension housing. These sur­
faces must be clean for proper adapter alignment and speedometer operation.
(2) Lubricate adapter oil seal and O-ring with
transmission fluid.

21 - 356 NP241
TRANSFER
CASE

•
TRANSFER
CASE
REMOVAL

(1) Raise vehicle.
(2) Position drain oil container under transfer case.
(3) Remove transfer case drain plug and drain lu­
bricant into container. (4) Disconnect wires at vehicle speed sensor.
(5) Disconnect vacuum hoses at vacuum switch.
(6) Disconnect transfer case shift lever from range
lever. (7) Remove skid plate and skid plate crossmember.
(8) Support transmission with jack stand.
(9) Remove rear crossmember.
(10) Mark front and rear propeller shaft yokes for
assembly reference. (11) Remove front and rear propeller shafts.
(12) Support transfer case with suitable jack. Se­
cure transfer case to jack with safety chains. (13) Remove nuts attaching transfer case to trans­
mission. (14) Move transfer case assembly rearward until
free of transmission output shaft. (15) Lower jack and move transfer case from under
vehicle. (16) Remove all gasket material from rear of
transmission adapter housing.

TRANSFER CASE
INSTALLATION
(1) Apply Mopar Perfect Seal, silicone sealer, or
Permatex No. 2 to both sides of transfer case-to-
transmission gasket. Then position gasket on trans­ mission.
(2) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by ro­
tating transfer case rear output shaft yoke if neces­ sary. Do not install any transfer case attaching
nuts until the transfer case is completely seated against the transmission.
(3) Install and tighten transfer case attaching nuts
to 47 N*m (35 ft. lbs.). (4) Install rear crossmember.
(5) Remove jack stand from under transmission.
(6) Align and connect propeller shafts.
(7) Connect speed sensor wires and vacuum switch

hoses.
(8) Connect transfer case shift lever to range lever.
Tighten lever locknut to 10 N*m (90 in. lbs.). (9) Fill transfer case with recommended transmis­
sion fluid. (10) Install transfer case fill plug.
(11) Install skid plate and skid plate crossmember.
(12) Lower vehicle.

TRANSFER CASE DISASSEMBLY
(2) Remove rear retainer (Figs. 2-3). Remove and
discard retainer seal. (3) Remove upper snap ring that retains speedom­
eter gear on shaft. Then remove speedometer gear (Fig. 1).

Fig.
1
Snap Ring
And Speedometer Gear
Removal/
Installation

(4) Remove shaft lower snap ring (Fig. 2)
(5) Remove oil pump. Remove and discard oil
pump seal. (6) Loosen rear case by prying corners loose to
break sealant bead (Fig. 3).

Fig.
2 Removing/Installing Shaft
Lower
Snap Ring
(7) Remove rear case from front case (Fig. 4)
(8) Remove oil pickup screen, tube and magnet
from rear case.

DRIVE CHAIN, SPROCKET, SHIFT FORK
AND

MAINSHAFT SHAFT REMOVAL
(1) Remove mode spring from shift rail (Fig. 5).
(2) Remove driven sprocket snap ring (Fig. 6).
(3) Remove sprocket and drive chain (Fig. 7). Tilt
mainshaft for clearance if necessary.
RETAINER
AND
REAR CASE
REMOVAL

(1) Remove indicator switch from front case.

•

NP241 TRANSFER
CASE
21 - 361

Fig.
21
Removing
Mainshaft Pilot Bearing
Fig.
22 Installing Mainshaft Pilot Bearing (2) Remove bearing with Tool Handle C-4171 and
Remover C-4610 (Fig. 24).
(3) Clean bearing bore thoroughly.
(4) Install new bearing with Handle C-4171 and
Installer C-4609 (Fig. 25).
(5) Install new seal in rear retainer.

FRONT
OUTPUT
SHAFT
FRONT
BEARING
REPLACEMENT
(1) Remove bearing from front case bore with Tool
Handle C-4171, Remover C-4610 and a shop press (Fig. 26).
(2) Clean bearing bore thoroughly.
(3) Install new bearing with Tool C-4210, Handle
C-4171 and a shop press (Fig. 27).

FRONT
OUTPUT
SHAFT
REAR BEARING
REPLACEMENT
(1) Remove bearing from rear case bore with Re­
mover Tools L-4518-1 and L-4454-1 (Fig. 28).
(2) Clean bearing bore thoroughly.
Fig.
23
Removing
Rear Retainer
Seal

Fig.
24
Removing
Mainshaft Rear (Output) Bearing (3) Install new bearing with Handle C-4171 and
Installer C-4608 (Fig. 29).

TRANSFER
CASE
ASSEMBLY
(1) Lubricate transfer case components with auto­
matic transmission fluid during assembly. (2) If transfer case bearings were replaced, verify
that new bearings do not block any oil feed holes. (3) Assemble input gear, thrust washer and low
range gear. Be sure low range snap ring is fully seated. (4) Install input and low range gear assembly in
front case. Secure input gear with snap ring (Fig.
11).
(5) Install shift sector and new sector shaft seals.
Install range lever on sector shaft and tighten lever
locknut to 30 N*m (22 ft. lbs.) torque. (6) Install range fork and hub (Fig. 9).

NP241
TRANSFER CASE
21 - 363
(16) Align and install rear case on front case. In­
stall and tighten rear case-to-front case bolts to 27-34
Nnn (20-25 ft. lbs.). (17) Install lower snap ring on mainshaft (Fig. 2).
(18) Install speedometer gear and upper snap ring
(Fig. 1).
(19) Install new seals in retainers if necessary.
(20) Apply 3 mm (1/8 in.) wide bead of Mopar gas­
ket maker, silicone adhesive/sealer, Loctite 518, or
Loctite 573 to sealing surface of rear retainer. Then install retainer and tighten retainer bolts to 31 Nnn
(23 ft. lbs.).
(21) Install yokes, seal washers and retaining nuts.
Tighten yoke nuts to 176-271 Nnn (130-200 ft. lbs.)
torque.
(22) Install vacuum switch. Tighten switch to 27
Nnn (20 ft. lbs.). (23) Fill transfer case with Mopar ATF Plus, type
7176 transmission fluid.

21 - 364
TRANSMISSION/TRANSFER
CASE
SPECIFICATIONS
•

AUTOMATIC TRANSMISSION
GENERAL SPECIFICATIONS

TRANSMISSION
MODEL
32RHI42RH
'36RH/37RHI46RH

Oil Pump Clearances (all)
0.089-0.190
mm

(0.0035-0.0075
in)
0.089-0.190
mm

(0.0035-0.0075
in)
Planetary End Play
0.127-1.22
mm

(0.005-0.048
in)
0.15-1.22
mm

(0.006-0.048
in)
Input Shaft End Play
0.56-2.31
mm

(0.022-0.091
in)
0.86-2.13
mm

(0.034-0.084
in)
Clutch Pack Clearance: Front Clutch - 3
Disc

Front Clutch - 4
Disc

Front Clutch - 5
Disc

Rear Clutch - 3
Disc

Rear Clutch - 4
Disc
1.88-3.17
mm

(0.074-0.125
in)
1.70-3.40
mm

(0.067-0.134
in)

1.90-3.86
mm

(0.075-0.152
in)

0.81-1.40
mm

(0.032-0.055
in)

0.81-1.40
mm

(0.032-0.055
in)
1.78-3.28
mm

(0.070-0.129
in)
2.08-3.83
mm

(0.082-0.151
in)

0.64-1.14
mm

(0.025-0.045
in)
Clutch
Disc
Usage:

Front Clutch
Rear Clutch
Overdrive Clutch (Gas)
Overdrive Clutch (Diesel) Direct Clutch 32RH
42RH 36RH/37 RH 46RH
Clutch
Disc
Usage:

Front Clutch
Rear Clutch
Overdrive Clutch (Gas)
Overdrive Clutch (Diesel) Direct Clutch 4
4
4
4 4
6 3/4
4 3/4
4
4

5
8
Front Clutch Spring
Usage
1 1
9
9/11

Band
Adjustments:
(backed off from 72 in. lbs.) Front
Band

Rear
Band
2Vi
4 2Yi
4 214

2
Th
2
Recommended Fluid (all)
MOPAR
ATF
Plus,
Type 7176 Automatic Transmission Fluid

J9321-210

32RH/36RH/37RH
SPACER/THRUST
PLATE/SNAP
RING
SPECIFICATIONS
TRANSMISSION
MODEL

COMPONENT
32RH 36RH/37RH
Front Clutch Thrust Washer
(on reaction shaft
support
hub) .061 in.
.061 in
.084 in
.102 in
Rear Clutch Thrust Washer
(on clutch
retainer)
.061 in
.061 in
Output Shaft Thrust Plate (on Output shaft pilot hub)
.060-.063
in

.060-.063
in
Output Shaft Thrust Washer (in
rear
clutch hub)
.052-.054
in

.068-.070
in
.083-085
in
.068-.070
in
Rear Clutch Pack
Snap
Ring
.068 in
.060 in
.076 in
.098 in .060 - .062 in
.074 - .076 in
.088 - .090 in .106 - .108 in
Planetary Geartrain
Snap
Ring

(At
front
end of output shaft) .040 - .044 in
.062 - .066 in .082 - .086 in .048 - .052 in
.055 - .059 in .062 - .066 in
J922M42
TRANSMISSION/TRANSFER
CASE
SPECIFICATIONS