1993 DODGE TRUCK brake fluid

CLUTCH
6 - 1

CLUTCH

CONTENTS
page

CLUTCH
DIAGNOSIS
2

CLUTCH
COMPONENTS

MECHANICAL COMPONENTS
The clutch mechanism
in
AD
models with
a gas or

diesel engine consists
of a
single, dry-type clutch disc and
a
diaphragm style clutch cover.
A
hydraulic
linkage
is
used
to
engage/disengage
the
clutch disc
and cover.
The transmission input shaft
is
supported
in the

crankshaft
by a
bearing.
A
sleeve type release bear­
ing
is
used
to
operate
the
clutch cover pressure plate.
The release bearing
is
operated
by a
release fork
in

the clutch housing.
The
fork pivots
on a
ball stud
mounted inside
the
housing.
The
release fork
is
actu­ ated
by a
hydraulic slave cylinder mounted
in the

housing.
The
slave cylinder
is
operated
by a
clutch master cylinder mounted
on the
dash panel.
The
cyl­
inder push
rod is
connected
to the
clutch pedal.
The clutch disc
has
cushion springs
in the
disc
hub.

The clutch disc facing
is
riveted
to the hub. The
fac­ ing
is
made from
a
non-asbestos material.
The
clutch
cover pressure plate
is a
diaphragm type with
a one-

piece spring
and
multiple release fingers.
The
pres­ sure plate release fingers
are
preset during
manufacture
and are not
adjustable.
A
265 mm
clutch disc
and
cover
are
used
in
models
with
a 3.9L
engine.
A 280 mm
clutch disc
and
cover are used
in
models with
a 5.2L, or
5.9L engine.
A
330 mm
clutch disc
and
cover
are
used
in
models
equipped with
the
optional
5.9L
Cummins diesel
en­

gine.
Some diesel models
are
also equipped with
a

clutch pedal interlock switch.
The
switch
is in
circuit
with
the
starter relay
and is
actuated
by the
clutch
pedal
and
push
rod. The
clutch pedal must
be
fully depressed
in
order
to
start
the
engine.

HYDRAULIC LINKAGE COMPONENTS
The hydraulic linkage consists
of a
remote reser­
voir, clutch master cylinder, clutch slave cylinder and interconnecting fluid lines.
The clutch master cylinder
is
connected
to the

clutch pedal
and the
slave cylinder
is
connected
to

the clutch release fork.
The
master cylinder
is
mounted
on the
drivers' side
of the
dash panel adja­
cent
to the
brake master cylinder.
page

CLUTCH
SERVICE
11

CLUTCH LINKAGE FLUID
The clutch fluid reservoir, master cylinder, slave
cylinder
and
fluid lines
are
prefilled with fluid
at the

factory during assembly operations. The hydraulic system should
not
require additional
fluid under normal circumstances.
In
fact,
the
reser­
voir fluid level will actually increase
as
normal clutch wear occurs.
For
this reason,
it is
impor­
tant
to
avoid overfilling,
or
removing fluid from
the reservoir. If inspection
or
diagnosis indicates additional fluid
may
be
needed,
use
Mopar brake fluid,
or an
equiv­
alent meeting
SAE and DOT
standards J1703
and

DOT
3. Do not use any
other type
of
fluid.

CLUTCH
COMPONENT LUBRICATION
Proper clutch component lubrication
is
important
to satisfactory operation.
The
correct lubricant
and
not overlubricating
are
equally important. Apply rec­
ommended lubricant sparingly
to
avoid disc
and
pres­ sure plate contamination. Clutch
and
transmission components requiring
lu­

brication
are:
• pilot bearing
• release lever pivot ball stud
• release lever contact surfaces
• clutch disc
hub
splines
• clutch pedal pivot shaft bore
• clutch pedal bushings
• input shaft splines
• input shaft pilot
hub

• transmission front bearing retainer slide surface Do
not
apply grease
to any
part
of the
clutch
cover,
or
disc.

RECOMMENDED LUBRICANTS
Use Mopar multi-purpose grease
for the
clutch
pedal bushings
and
pivot shaft.
Use
Mopar high tem­
perature grease
(or
equivalent)
for all
other lubrica­
tion requirements. Apply recommended amounts
and
do
not
over lubricate.

8E
- 8 INSTRUMENT PANEL AND GAUGES

•

BRAKE

WARNING
LAMP
SWITCH TO BRAKE
WARNING LAMP

PR!
451

Fig.
6
Brake Warning
Lamp
Switch
depresses
the
brake pedal
and
observes
the
warning

lamp.

If
the
lamp fails
to
light, inspect
for:

•
a
burned
out
bulb
• disconnected socket
•
a
broken
or
disconnected wire
at the
switch. If
the
bulb
is not
burned
out and the
wire continu­
ity
is
proven, replace
the
brake warning switch.
The

switch
is in the
brake line
Tee
fitting mounted
on

the frame rail
in the
engine compartment below
the

master cylinder.

CAUTION:
If
wheel cylinder bleeder
was
opened

check
master cylinder fluid level.

On Diesel Models
The
Brake light
is
also con­
nected
to a
sensor that monitors vacuum
in the

brake booster system.
The
Brake light when
lit
indi­ cates
LOW
VACUUM. Refer
to
Group
5 -
Brakes
for

more information.

TEMPERATURE
GAUGE CIRCUIT TEST
(1) Remove temperature gauge. Refer
to
Gauge
Re­

placement. (2) Check continuity
in the
wire between
the
tem­
perature sensor
and the
temperature gauge (sensor
input
pin)
(Figs.
7, 8 and 9).
(3) With
the
ignition switch
in the ON
position,
check
for
battery voltage across
the B + pin and the

Ground
pin.
(TURN
IGNITION
KEY
"ON"

(DO
NOT
START
ENGINE

I
RELEASE
PARKING
BRAKE)
I

I

[
WARNING
LIGHT
GOES
I
"ON"
I

1
(LIGHT
SHOULD
BE
"OFF")!
X

APPLY PARKING BRAKE (WARNING
LIGHT

SHOULD
GO "ON")

BRAKE
SYSTEM
LEAKING FLUID
X

WARNING
LIGHT

FAILS
TO GO "ON" GROUNDED WIRING
BULB
BURNED
OUT

SHORTED PARKING BRAKE
OR BRAKE WARNING SWITCH

X
DISCONNECTED
OR
FAULTY

BULB
SOCKET
FAULTY BRAKE SYSTEM PROPORTIONING VALVE
UNIT*
BROKEN
WIRE
OR
WIRE
DISCONNECTED
AT
PARKING
BRAKE
SWITCH

X

FAULTY PARKING
BRAKE
SWITCH

X

APPLY SERVICE BRAKES
(WARNING
LIGHT

SHOULD
NOT GO "ON")

JZ
X

TEST SERVICE BRAKE WARNING
SYSTEM FUNCTION*

X
WARNING
LIGHT
GOES

"ON"

WARNING
LIGHT

DOES
NOT GO "ON"
BRAKE
SYSTEM
LEAKING FLUID
OPEN CIRCUIT
IN
WIRING
TO SERVICE BRAKE SWITCH
X

GROUNDED WIRING
OR

SHORTED BRAKE WARNING SWITCH

LOOSE
BULKHEAD CONNECTOR
X

FAULTY BRAKE SYSTEM
PROPORTIONING VALVE
UNIT*

FAULTY SERVICE BRAKE SWITCH

X
•TESTS
ARE
DESCRIBED
IN APPROPRIATE
SECTION
OF
SERVICE MANUAL
FAULTY SERVICE BRAKE
SYSTEM PROPORTIONING VALVE
UNIT*
PR1449A

13
- 32
FRAME
AND
BUMPERS

• r INSTALLATION
(1) Verify the insulators and spacers are positioned
on the frame holddown brackets (Figs. 4 and 5). (2) Position the cab on the frame.
(3) Install the cab holddown nuts and bolts (Figs. 4
and 5). Tighten the nuts to 68 N-m (50 ft. lbs.)
torque. Tighten the bolts to 81 Nnn (60 ft. lbs.)
torque. (4) Position the restraint cable ends on the cab
rear seat belt anchor bolts. Install the retaining nuts.
Tighten the nuts to 45 N-m. (33 ft. lbs.) torque.
(5) Connect the steering shaft to the steering gear.
(6) Connect the tubing to the clutch master cylin­
der (if equipped).
(7) Connect the transmission and transfer case (if
equipped) shift linkage. (8) Connect the cable to the starter motor.
(9) Connect the heater and A/C hoses.
(10) Connect the engine controls.
(11) Connect the parking brake cable and the
brake lines.
(12) Connect the wire harness connectors to the
engine components and to the frame. (13) Connect all remaining items between the cab
and the frame components. (14) Install the battery in the tray. Connect the ca­
bles to the terminals. (15) Inspect the installation of the cab on the
frame and verify that:
• All connecting hardware is tightened
• All fluids and lubricants are full
• All electrical, engine, drivetrain and chassis com­
ponents are operational.

CARGO
BOX REMOVAL The cargo box is attached to the rear frame struc­
ture with holddown bolts (Fig. 6). The box can be re­ moved for repair or service access. Refer to the
associated component procedures when necessary.
(1) Disconnect the battery cables from the termi­

nals.

(2) Disconnect the rear lamp wire harness connec­

tors.
(3) Support the exhaust pipe. Disconnect the sup­
port hanger from the cargo box. (4) Loosen the clamps. Disconnect the fuel and
vent hoses from the nozzle tubes (Fig. 7). (5) Remove the cargo box holddown bolts (Fig. 6).
The bolts are accessible from the underside of the cargo box. (6) Identify, mark and retain the spacers (if used)
for installation reference. (7) Remove the cargo box from the frame (Fig. 6).

CARGO CARGO
BOX

FWD HOSE CLAMP
J9123-551
Fig.
7
Fuel
& Vent
Hoses
INSTALLATION
(1) Position cargo box on the frame (Fig. 6).
(2) Insert the spacers. Install the holddown bolts
(Fig. 6). Tighten the bolts to 47 Nnn (35 ft. lbs.)
torque.
(3) Connect the fuel and vent hoses to the nozzle
tubes (Fig. 7). Tighten the fuel hose clamp screw to 3
Nnn (20 in. lbs.) torque. Tighten the vent hose clamp screw to 2 Nnn (14 in. lbs.) torque.
(4) Connect the tail pipe to the hanger on the
cargo box. Remove the support. (5) Connect rear lamp wire harness connectors.
(6) Connect the battery cables to the terminals.
(7) Inspect the installation of the cargo box on the
frame and verify that:
• All connecting hardware is tightened • All electrical system components are operational

•

FUEL
SYSTEM
14 - 87
ENGINE
WARM-UP

• The PCM may start the air intake heater post-heat
cycle depending on intake air temperature. If manifold air temperature was at or below 15°C (59°F) when the
ignition switch was turned on, the cycle is started.
• If intake manifold air temperature is below 32°C
(90°F),
the KSB solenoid will be energized through
the air temperature switch. The solenoid remains en­ ergized until the air temperature switch opens. The
switch opens when intake manifold air temperature
is above 32°C (90°F).
• If the coolant temperature is below 16°C (60° F),
the transmission will not be allowed to enter over­ drive (automatic transmission).
• The PCM will turn on the water-in-fuel lamp if a signal is received from the water-in-fuel sensor.

CRUISE
OR
IDLE

• The PCM monitors intake manifold air tempera­
ture through the charge temperature sensor input. • If intake manifold air temperature is below 32°C
(90°F),
the KSB solenoid will be energized through
the air temperature switch. The solenoid remains en­ ergized until the air temperature switch opens. The switch opens when intake manifold air temperature
is above 32°C (90°F).
• The air intake heater post-heat cycle will be com­
pleted, if it is not already over.
• The vehicle speed sensor, engine speed sensor and
throttle position sensor inputs are used to control
transmission overdrive operation.
• If the coolant temperature is below 16° C (60° F),
the transmission will not be allowed to enter over­ drive (automatic transmission).
• If the transmission thermo-switch is open, the
transmission will not be allowed to enter into over­
drive (automatic transmission). If the switch opens
when the vehicle is in overdrive, the transmission
will be downshifted. The transmission thermo-switch opens at 134°C (273°F).
• The thermo-switch will close once the transmission
fluid temperature drops to 116°C (240°F). • The PCM will turn on the water-in-fuel lamp if a signal is received from the water-in-fuel sensor.

ACCELERATION
• The vehicle speed sensor, engine speed sensor and
throttle position sensor inputs are used to control
transmission overdrive operation.
• If the coolant temperature is below 16° C (60° F),
the transmission will not be allowed to enter over­
drive (automatic transmission).
• If intake manifold air temperature is below 32°C
(90°F),
the KSB solenoid will be energized through
the air temperature switch. The solenoid remains en­ ergized until the air temperature switch opens. The
switch opens when intake manifold air temperature
is above 32°C (90°F). • If the transmission thermo-switch is open, the
transmission will not be allowed to enter into over­
drive (automatic transmission). If the switch opens
when the vehicle is in overdrive, the transmission
will be downshifted. The transmission thermo-switch opens at 134°C (273°F). The thermo-switch will close
once the transmission fluid temperature drops to 116°C (240°F).
• The PCM will turn on the water-in-fuel lamp if a
signal is received from the water-in-fuel sensor.
• If the speed control system resume/accelerate func­
tion is being used, the PCM will only allow the vehi­
cle to accelerate at a predetermined rate. If a speed
control has been set and the resume/accelerate but­
ton is momentarily pushed in, the PCM will increase
vehicle speed by two miles per hour.
• If the brakes are applied, the PCM will disable the
speed control.

DECELERATION

• The vehicle speed sensor, engine speed sensor and
throttle position sensor inputs are used to control
transmission overdrive operation.
• If the coolant temperature is below 16° C (60° F),
the transmission will not be allowed to enter over­ drive (automatic transmission).
• If the transmission thermo-switch is open, the trans­
mission will not be allowed to enter into overdrive (au­
tomatic transmission). If the switch opens when the
vehicle is in overdrive, the transmission will be down­ shifted. The transmission thermo-switch opens at 134°C (273°F). The thermo-switch will close once the transmis­
sion fluid temperature drops to 116°C (240°F).
• The PCM will turn on the water-in-fuel lamp if a
signal is received from the water-in-fuel sensor.
• If intake manifold air temperature is below 32°C
(90°F),
the KSB solenoid will be energized through
the air temperature switch. The solenoid remains en­ ergized until the air temperature switch opens. The
switch opens when intake manifold air temperature
is above 32°C (90°F).
• If the speed control system coast/set function is be­
ing used, the PCM will only allow the vehicle to de­ celerate at a predetermined rate. If the coast/set
switch is pushed while the system is operating, the
PCM will set speed control to the rate the vehicle is
traveling at when the switch is released. • If the brakes are applied, the PCM will disable the speed control.

IGNITION SWITCH
OFF
• When the ignition switch is turned to the off posi­
tion, the PCM still receives battery voltage through
the battery input. Battery voltage is needed to keep
PCM memory alive. The PCM memory stores diag­ nostic trouble code (DTC) messages and the mini­
mum TPS value from the previous key-on.

19
- 8
STEERING

POWER
STEERING
SYSTEM
DIAGNOSIS

LOOSE
STEERING

CONDITION
POSSIBLE
CAUSE
CORRECTION

EXCESSIVE
WHEEL

KICKBACK
OR
TOO

MUCH
STEERING
WHEEL
PLAY
1.
Air in system
2.
Gear
loose
on
crossmember

3.
Worn/broken intermediate shaft
4.
Free
play in steering column
5.
Loose
ball
joints

6. Front wheel bearings
loose
or worn
7.
Loose
outer tie rod
ends

8.
Loose
inner
tie
rod
ends

9.
Defective steering gear
rotary
valve
1.
Add
fluid.

2.
Check
gear
to
crossmember
mounting bolts. Tighten
to
specification,

3.
Check
for worn universal
joint
ond
broken isolator.
Replace
intermediate shaft
if

worn.

4.
Check
and replace
as
required. 5.
Check
and replace
as
required.

6.
Tighten hub nut or replace
with
new parts
as
necessary.

7.
Check
and replace
as
required.
8.
Replace
gear.

9.
Replace
gear.

VEHICLE
LEADS
TO THE
SIDE

CONDITION
POSSIBLE
CAUSE
CORRECTION

WHEEL
DOES
NOT

WANT
TO
RETURN
TO
CENTER
POSITION
1. Radial
tire
lead
2. Front
end
misaligned

3.
Wheel braking
4.
Unbalanced
steering
gear
valve.
(If this is the
cause,
the steering
efforts
will
be very
light
in

direction
of
lead and heavier in the opposite
direction)
1.
Rotate
tires
as
recommended in Tire

Service.

2. Align
front
end
as
recommended
in
Wheel
Alignment
Service
Procedure.

3.
Check
for
dragging
brakes
as
directed
in
Brake
Service
Procedure.

4.
Checking
for
pull
with
outer
tie
rod end
disconnected.
If verified, replace gear.

9119-6

19
- 14
STEERING

• (9) Install the fluid hoses to the power steering
pump, Tighten the pressure fitting at the pump to 30
N*m (22 ft. lbs.) torque.
(10) Install and clamp the hose on the vacuum
pump. (11) Fill the reservoir with power steering fluid
only. If necessary, refer to Pump Initial Operation
for detailed instructions.
(12) Start and run the engine. Check the operation
of the brakes, if necessary refer to Group 5, Brakes
for additional information.

PUMP REPLACEMENT—GASOLINE ENGINE

REMOVAL

WARNING:
DO NOT
REMOVE
THE
WATER PUMP COOLANT TUBE UNLESS
THE
COOLANT SYSTEM HAS BEEN DEPRESSUR1ZED
AND
DRAINED*
WARNING:
DO NOT
ATTEMPT
TO
REMOVE
THE
PUMP
WITHOUT
REMOVING
THE
BELT FIRST.
THE

AUTOMATIC TENSIONER
IS
UNDER
A
HIGH
SPRING
LOAD.

(1) Remove the serpentine drive belt. Rotate ten­
sioner clock-wise and hold in place, and remove belt
(Fig. 10).

Fig.
10 Serpentine Belt Removal/Installation
(2) Clamp the fluid return hose and disconnect the
hoses from the power steering pump. Cap the fit­

tings.

(3) Remove battery ground cable and nut at stud.
Unthread stud from cylinder head, do not remove
from bracket. Loosen upper bracket bolt. Remove the lower bracket to engine block bolts. Pivot the pump
assembly past the coolant tube. Remove the upper
stud. Remove upper bolt from cylinder head. The
steering pump and mounting bracket will be re­
moved from engine as an assembly.
(4) Remove the pump pulley, refer to the procedure
below. This will allow access to the pump attaching screws.

(5)
Remove the bracket to pump attaching screws
(Fig. 11).

Fig.
11
Pump
Removal/Installation

INSTALLATION
(1) Install the bracket to pump mounting screws
(Fig. 11). Tighten to 54 N-m (40 ft. lbs.). (2) Install the pump pulley, refer to the procedure
below.
(3) Position the steering pump (with pulley) and
mounting bracket on the engine block (Fig. 11). In­ stall the upper stud and bolt in bracket. Pivot the
pump down past the coolant tube. Install the lower
bolts in bracket (Fig. 11). (4) Install the bracket to engine block attaching
bolts (Fig. 11). Tighten the bolts and nut to 41 N*m (30 ft. lbs.).
(5) Connect the fluid hoses to the pump. (6) Install the serpentine drive belt. Rotate ten­
sioner clock-wise and hold in place, slip the belt over
the pulleys. Refer to Group 7, Cooling for belt rout­ ing.

CAUTION:
Do not use
automatic
transmission
fluid
to
fill the
reservoir.

(7) Fill the reservoir with power steering fluid
only. If necessary, refer to Pump Initial Operation
for detailed instructions.

•

AUTOMATIC TRANSiISSiOi-32RH/38RH/37RH/42RH/4eRH
21 - 81 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING

INDEX

page

Air Testing Clutch
and
Band Operation
91

Analyzing
the
Road Test
87
Converter Housing Fluid Leak Diagnosis
.......
92
Converter
Stall
Test
90
Diagnosis
Charts
and
Hydraulic Flow Diagrams
. . 95

Fluid Contamination
86

Fluid Level
and
Condition
85

GENERAL
INFORMATION
The diagnosis
and
testing information
in
this sec­
tion applies
to
three
and
four speed models alike.
Di­
agnosis
and
test procedures apply
to all
models
except where indicated. Diagnosis information that
only applies
to
42RH/46RH models
is
noted.
Automatic transmission problems
can be a
result
of

poor engine performance, incorrect fluid level, incor­
rect linkage adjustment, band
or
hydraulic control
pressure adjustments, hydraulic system malfunctions
or electrical/mechanical component malfunctions.
Begin diagnosis
by
checking
the
easily accessible
items such
as:
fluid level
and
condition, linkage
ad­

justments
and
electrical connections
on
4-speed mod­
els.
A
road test will determine
if
further diagnosis
is
necessary. Procedures outlined
in
this section should
be
per­
formed
in the
following sequence
to
realize
the
most accurate results:
• Preliminary diagnosis
• Fluid Level
and
condition • Linkage Adjustment
• Road test
• Hydraulic pressure test • Stall test
•
Air
pressure tests
• Leak Tests
• Analyze test results
and
consult diagnosis charts

PRELIMINARY
DIAGNOSIS
Two basic procedures
are
required.
One
procedure
for vehicles that
are
driveable
and an
alternate pro­ cedure
for
disabled vehicles (will
not
back
up or

move forward).

Vehicle
Is
Driveable
(1) Check fluid level
and
condition.
(2) Adjust throttle
and
gearshift linkage
if
com­
plaint
was
based
on
delayed, erratic,
or
harsh shifts.
(3)
On
4-speed models, check electrical connections
at dash switch
and
transmission case. Turn control
switch
to ON
position before proceeding. (4) Road test
and
note transmission operating
characteristics.
page

Gearshift Linkage
87

General
Information
85

Hydraulic Pressure Test
88

Overdrive Fourth Gear
Electrical
Controls
......
86
Preliminary Diagnosis
85

Road
Test
87

Throttle
Valve Cable
86

(a)
If
acceleration
is
sluggish,
or if
abnormal
throttle opening
is
needed
to
maintain normal speeds with
a
properly tuned engine, perform
a

stall test
to
check converter clutch operation. (b)
On
42RH/46RH,
if
fourth gear upshift does
not occur, check overdrive solenoid
and
switch wir­ ing
for
opens, shorts, grounds.
(c)
If
slippage
and
engine flare
is
noted, perform
hydraulic pressure test
and air
pressure test
to
check clutch-band-governor operation.

Vehicle
Is
Disabled
(1) Check fluid level
and
condition.
(2) Check
for
broken, disconnected throttle link­

age.

(3) Check
for
cracked, leaking cooler lines,
or

loose, missing pressure port plugs.
(4) Raise vehicle, start engine, shift transmission
into gear
and
note following:
(a)
If
propeller shafts turn
but
wheels
do not,

problem
is
with differential
or
axle shafts. (b)
If
propeller shafts
do not
turn
and
transmis­
sion
is
noisy, stop engine. Remove
oil pan, and

check
for
debris.
If pan is
clear, remove transmis­
sion
and
check
for
damaged drive plate, converter,
oil pump
or
input shaft.
(c)
If
propeller shafts
do not
turn
and
transmis­
sion
is not

noisy, perform hydraulic pressure test
to
deter­
mine
if
problem
is a
hydraulic
or
mechanical.

FLUID LEVEL AND CONDITION
(1) Place vehicle
on
level surface. This
is
impor­
tant
for an
accurate reading. (2)
Do not
check level until fluid
is at
normal
op­

erating temperature
of
approximately 82°C (180°F).
This
is
necessary
to
avoid false readings which could
produce under
or
over fill condition, (3) Fully apply parking brakes.
(4) Start
and run
engine
at
curb idle speed. Then
shift transmission through
all
gear ranges
and
back
to Neutral. (5) Clean
top of
filler tube
and
dipstick
to
keep dirt
out
of
tube.

21 - 90
AUTOMATIC
TRANSMISSION—32RH/36RH/37RH/42RH/46RH

• (4) Note pressure with engine at curb idle speed
and rear wheels stopped. Pressure should be zero to 1-1/2 psi maximum. If pressure exceeds this figure,
governor valve or weights are sticking open.
(5) Slowly increase engine rpm and observe speed­
ometer and pressure test gauge. Governor pressure should increase in proportion to indicated vehicle
speed (or approximately 1 psi for every 1 mph).
(6) Pressure rise should be smooth and drop back
to 0 to 1-1/2 psi when wheels are braked to a stop and engine returns to curb idle speed.
(7) Compare results of the pressure tests with the
Pressure Test Analysis Charts (Figs. 6 and 7).

Test
Six—42RH/46RH
Transmission
In Overdrive Fourth
Gear

This test checks line pressure at the overdrive
clutch in fourth gear range. Use 300 psi Test
Gauge C-3292 for this test.
(1) Raise vehicle and connect test gauge to over­
drive clutch pressure port (Fig. 5). (2) Lower vehicle to enough to allow entry into
drivers seat. Leave vehicle wheels approximately one
foot off shop floor.
(3) Secure test gauge where it can be viewed from
drivers seat.
(4) Verify that overdrive control switch is in ON
position. (5) Start engine and shift into D range.
(6) Increase engine rpm gradually until 3-4 shift
occurs and note gauge pressure. (7) Pressure should be 469-496 kPa (68-72 psi)
with closed throttle and increase to 620-827 kPa (90- 120 psi) at 1/2 to 3/4 throttle. Note that pressure will
increase to 896 kPa (130 psi) or more at full throttle. (8) Refer to pressure test chart (Fig. 7) for pressure
diagnosis.

CONVERTER
STALL
TEST
Stall testing involves determining maximum en­
gine rpm obtainable at full throttle with the rear
wheels locked and the transmission in D range. This
test checks the holding ability of the converter over­
running clutch and both of the transmission clutches. When stall testing is completed, refer to the Stall
Speed Specifications chart and Stall Speed Diagnosis
guides.

WARNING:
NEVER
ALLOW
ANYONE
TO
STAND

IN
FRONT
OF THE
VEHICLE
DURING
A
STALL

TEST.
ALWAYS
BLOCK
THE
FRONT
WHEELS
AND
APPLY
THE
SERVICE
AND
PARKING
BRAKES
DURING
THE
TEST.

STALL
TEST
PROCEDURE
(1) Connect tachometer to engine.
(2) Check and adjust transmission fluid level.
1EST
CONDITION
INDICATION

Line
pressure
OK during

any
one test
Pump
and regulator valve OK

Line
Pressure
OK in R
but low in D, 2, 1
Leakage
in
rear
dutch area
(servo,

dutch
seals,
governor
support

seal
rings)

Pressure
OK in 1, 2 but

low
in D3 and R
Leakage
in
front
dutch area
(servo,

dutch
seals,
retainer
bore,
pump
seal
rings)

Pressure
OK in 2 but low in

R
and 1
Leakage
in
rear
servo

Front
servo
pressure
in 2
Leakage
in
servo;
broken
servo

ring
or
cracked
servo
piston

Pressure
low in all
positions
Cogged
filter,
stuck
pressure

regulator valve, worn or
defective
pump

Governor
pressure
too
high
at idle
speed:
Governor
valve
sticking
open

Governor
pressure
low at all
mph
figures
Governor
valve
sticking
dosed

Lubrication
pressure
low at all

throttle
positions
Clogged
oil cooler or
lines,
seal

rings
leaking,
output shaft

plugged
with
debris,
worn

bushings
in
pump
or dutch

retainer
J9021-34

Fig.
6
Pressure
Test
Analysis
Chart (32RH/36RH/
37RH)

(3) Start and run engine until transmission fluid
reaches normal operating temperature. (4) Block front wheels.
(5) Fully apply service and parking brakes.
(6) Open throttle completely for no more than five
seconds and record maximum engine rpm registered
on tachometer.

CAUTION:
Stall testing
causes
a rapid increase in

transmission
fluid
temperature. Do not
hold
the

throttle
open
any
longer
than
five
seconds.
If more
than one stall test is required, run the engine at 1000 rpm
with
the
transmission
in Neutral for at

least
20
seconds
to
cool
the fluid.
(7) If engine speed exceeds maximum shown in
stall speed chart, release accelerator pedal immedi­
ately. This condition indicates transmission clutch
slippage is occurring.
(8) Shift transmission into Neutral. Operate en­
gine for 20 seconds. Stop engine, shift transmission
into Park and release brakes.
(9) Stall speeds should be: 1800-2100 rpm with
3.9L engine and 1700-2000 rpm with 5.2L/5.9L en­

gines.

(10) Refer to Stall Test Diagnosis.