
•
FUEL
SYSTEM
14 - 121
Fig.
49
Throttle
Position
Sensor
(TPS) Testing (4) With the fuel injection pump throttle lever con
tacting the low idle speed screw (Fig. 50), TPS output should be 1 volt or slightly above. If not, the TPS
must be adjusted.
(5) The TPS nylon adapter (Fig. 51) is machined to
accept a 10 MM open end wrench. To adjust, gently
rotate the nylon adapter with a 10 MM open end
wrench to until correct voltage is obtained.
J9114-261
Fig.
50
Throttle
Lever
Contacting Low Idle
Speed Screw
(6)
Open throttle to the wide open position. The
spring load breakover lever should have moved off
the stop and rest against the breakover spring (Fig.
52).
If not, the throttle actuation rod must be ad
justed before adjusting TPS. Refer to Accelerator Pedal and Throttle Cable section of Group 14, Fuel Systems.
(7) With throttle held in wide open position, check
TPS output voltage. It should be 2.25 to 2.75 volts
higher than the output voltage is at closed throttle position. If not, gently rotate nylon adapter to obtain
correct voltage.
Fig.
51 Adjusting
Throttle
Position
Sensor
Fig.
52 Correct Breakover
Spring
Position
WATER-IN-FUEL
SENSOR
REMOVAL
(1) Remove fuel/water separator filter. Refer to Fu
el/Water Separator Filter Removal.
(2) Remove the square cut O-ring from the filter
connector at the bottom of the fuel heater (Fig. 53). (3) Drain the fuel/water separator filter. Remove
the water-in-fuel sensor, O-ring and fuel/water drain
valve assembly from separator filter (Fig. 53).
INSTALLATION
(1) Apply a light film of clean engine oil to sealing
surface of WIF sensor. (2) Install WIF sensor into new fuel/water separa
tor filter.
(3) Fill separator filter with clean fresh fuel.
(4) Apply a light film of clean engine oil to sealing
surface of separator filter.
(5) Install a new square cut O-ring to the filter
connector on the bottom of the fuel heater.

19
- 16
STEERING
•
EXPANSION PLUG
-
DO NOT
REMOVE; IF DEFORMED
OR
DISLODGED,
REPLACE
HOUSING
RESERVOIR
HOUSING
CAP
SEAL FITTING
75 N-m
(55
FT.
LBS.)
9119-9
(5)
Start the engine. Slowly turn
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock. (8) Stop the engine. Check the fluid level and refill
as required. (9) If the fluid is extremely foamy, allow the vehi
cle to stand a few minutes and repeat the above pro cedure.
Fig.
14
Pump
and Reservoir
the steering
VALVE
AND
SPRING
J8919-101
Fig.
15 Flow Control Valve/Spring
Installation

•
NV4500 MANUAL
TRANSMISSION
21 - 3
PTO
COVER
J9221-14
Fig. 2 NV4500 identification Tag Location
DRAIN
PLUG
J9221-80
Fig. 3 NV4500 Drain And Fill Plug Locations
o
0 ©
0 0©
J9221-13
Fig. 4 NV4500 Shitt Pattern
NOISY OPERATION Transmission noise is most often a result of worn
or damaged components. Chipped, broken gear or
synchronizer teeth and brinnelled, spalled bearings
all cause noise.
Abnormal wear and damage to internal compo
nents is frequently the end result of insufficient lu
bricant, non-recommended lubricants, or improper operation.
SLIPS
OUT OF
GEAR
Transmission disengagement may be caused by
misaligned or damaged shift components, or worn
teeth on the mainshaft gears or synchro components. Incorrect assembly will also contribute to gear disengagement.
LOW LUBRICANT LEWEL
Insufficient transmission lubricant is usually the
result of leaks, or inaccurate fluid level check or re
fill method.
Leaks will be evident by the presence of gear oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill condi
tion.
If air powered lubrication equipment is used to fill
a transmission, be sure the equipment is properly
calibrated. Equipment out of calibration can lead to
an underfill condition.
CLUTCH
PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash and noise.
A damaged pilot bearing will cause noise. If bear
ing damage is severe, drive gear misalignment and
hard shifting can also occur.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear clash.
Damaged or worn clutch hydraulic components, or
leaks in the fluid lines or cylinders will cause hard shifting and gear clash. Failure of one of the clutch
hydraulic cylinders can result in incomplete clutch release or engagement.
Verify that clutch components are all in good con
dition before removing the transmission for repair.
TRANSMISSION
REMOVAL—2-WHEEL DRIVE
(1) Disconnect battery negative cable. (2) Shift transmission into Neutral.
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on lever. (4) Loosen nut that secures shift lever on transmis
sion stub lever. Then remove shift lever from stub le
ver. (5) Raise and support vehicle.
(6) Mark propeller shaft and axle yokes for align
ment reference. Use paint, scriber, or chalk to mark
yokes.
(7) Remove U-joint clamp strap screws and remove
clamps. (8) Remove propeller shaft.
(9) Disconnect and remove exhaust system Y-pipe.
(10) Disconnect wires at speed sensor and backup
light switch. (11) Support engine with adjustable safety stand
and wood block.

1
.
NW4500
MANUAL
TRANSMISSION 21 - 5 making transmission removal/installation easier.
Cylinder does not have to be removed completely. (28) Remove bolts attaching transmission to clutch
housing.
(29) Move transmission rearward until drive pin
ion clears clutch disc and release bearing. (30) Lower transmission and remove it from under
vehicle.
(31) If transmission will be overhauled, thoroughly
clean transmission exterior with solvent or steam
gun.
TRANSMISSION INSTALLATION-4-WHEEL DRIVE (1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com
ponents: • drive gear splines and pilot bearing hub • release bearing slide surface of front retainer
• pilot bearing
• release bearing bore
• release fork
• release fork ball stud
• propeller shaft slip yoke (2) Fill transmission with recommended lubricant.
Correct level is to bottom edge of fill plug hole. (3) Mount transmission on jack and position trans
mission under vehicle. Secure transmission to jack
with safety chains. (4) Raise transmission until drive gear is centered
in release bearing and clutch disc hub. (5) Move transmission forward and start drive gear
in release bearing and clutch disc. (6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after drive gear has entered clutch disc. (7) Install and tighten transmission-to-clutch hous
ing bolts to 108 N*m (80 ft. lbs.) torque. (8) Connect speed sensor and backup light switch
wires.
(9) Position transmission harness wires in clips on
shift cover. (10) Tighten slave cylinder attaching nuts and in
stall slave cylinder shield, if equipped.
(11) Install transmission mount on transmission or
rear crossmember. (12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Install transfer case on transmission jack. Se
cure transfer case to jack with safety chains. (15) Install new gasket on transmission adapter, or
coat adapter sealing surface with Mopar Gasket
Maker, or silicone adhesive sealer.
(16) Raise jack and align transfer case input gear
with transmission mainshaft.
(17) Move transfer case forward and seat it on
adapter.
(18) Install and tighten transfer case attaching
nuts to 47 N«m (35 ft. lbs.) torque.
(19) Connect transfer case shift lever to range le
ver on transfer case. (20) Align and connect propeller shafts. Tighten
U-joint clamp strap bolts to 19 N*m (170 in. lbs.)
torque.
(21) Check lubricant levels in transmission and
transfer case. Add lubricant if necessary.
(22) Install transfer case skid plate and crossmem
ber. Tighten attaching bolts/nuts to 41 N»m (30 ft. lbs.) torque.
(23) Install exhaust system components.
(24) Lower vehicle.
(25) Install transmission shift lever, boot and be
zel.
(26) Connect battery negative cable.

21 - 52 G360
MANUAL
TRANSMISSION
• (12) Disconnect wires at vehicle speed sensor and
backup light switch.
(13) Disconnect transfer case shift lever from lever
on transfer case.
(14) Temporarily support transmission with adjust
able jack stand. Then support transfer case with
transmission jack.
(15) Remove nuts attaching transfer case to trans
mission adapter and move transfer case away from
transmission rear retainer.
(16) Lower transfer case and move it from under
vehicle. Remove transfer case from transmission jack and place transfer case on workbench.
(17) Support transmission with transmission jack.
Secure transmission to jack with safety chains. Then
remove jack stand previously used to support trans
mission.
(18) Spread clamps that secure switch wires to
transmission top cover and remove wires from clamps. Move wires aside to protect them and pro
vide working clearance.
(19) Remove bolts attaching transmission rear
mount to crossmember.
(20) On some models, it is necessary to remove
screws attaching fuel line clamps to driver side
frame rail. Three clamps must be removed to so fuel lines can be moved for access to crossmember bolts at
this side of frame rail.
(21) Remove left and right crossmember-to-frame
braces and remove crossmember.
(22) Remove clutch slave cylinder shield.
(23) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever (Fig.
20).
This reduces pressure on lever and release bear
ing making transmission removal/installation easier. Cylinder does not have to be removed completely.
(24) Remove bolts attaching transmission to clutch
housing and remove transmission. Rock transmission slightly to help free input shaft from clutch disc and
release bearing.
(25) Support engine with wood block and another
adjustable jack stand.
TRANSMISSION
INSTALLATION—4-WHEEL
DRIVE
(1) Mount transmission on jack stand. Secure
transmission to jack with safety chains.
(2) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of input shaft (Fig. 20) and following components:
CAUTION:
Do not use
excessive
amounts
of
grease.
This
practice
could
result in contamination of the
clutch
disc.
• input shaft splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bushing
• release bearing bore
• release fork
• release fork ball stud • propeller shaft slip yoke
(3) Align transmission and clutch housing. Move
transmission forward and start input shaft into re lease bearing and hub of clutch disc. (4) Rotate output shaft with socket or yoke to align
input shaft and clutch disc splines. If input shaft will
not rotate enough in neutral to align splines, it will
be necessary to shift transmission into third or fourth gear with screwdriver. (5) Seat transmission against clutch housing and
align bolt holes in transmission and housing. (6) Install and tighten transmission-to-clutch hous
ing bolts to 68 N-m (50 ft. lbs.). (7) Install rear crossmember and mount. Start all
crossmember bolts/nuts then tighten them to 68 N*m (50 ft. lbs.) torque. (8) Remove transmission jack.
(9) Install screws that attach fuel line clamps to
driver side frame rail. (10) Align clutch slave cylinder in housing and
tighten cylinder attaching nuts. (11) Install clutch slave cylinder shield.
(12) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires across top of transmission to sensor and switch and
connect wires.
(13) Install gasket and transfer case on transmis
sion rear retainer. Tighten transfer case attaching
nuts to 47 N-m (35 ft. lbs.) torque. (14) Check transmission and transfer case lubri
cant levels. Add lubricant if necessary and install fill
plugs.
(15) Connect transfer case shift lever to lever on
transfer case.
(16) Align and install propeller shafts. Tighten
U-joint clamp bolts to 19 N-m (14 ft. lbs.). (17) Install skid plate and crossmember. Tighten
skid plate and crossmember bolts/nuts to 41 N—m
(30 ft. lbs.) torque.
(18) Lower vehicle.
(19) Shift transmission into neutral if necessary.
(20) Lubricate shift lever ball and collar with Mo
par all purpose grease. (21) Align notches in shift lever ball and collar
and insert shift lever in shift tower. (22) Press shift lever and collar downward and in
stall shift lever snap ring. (23) Install boot over shift lever and onto shift
tower and tighten boot clamp securely. (24) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large
notch is forward then install lower boot attaching screws. (25) Thread or bolt shift lever extension to shift le
ver. Slide upper boot down extension. Position boot on plate and install boot attaching screws. (26) Install shift knob on extension (if removed).
(27) Connect battery negative cable.

•
AUTOMATIC TRANSiISSIO|-32RH/8iRH/37RH/42RH/4iRH
21 - 83 plate. The overdrive clutch also disengages the direct
clutch during 3-4 upshifts. As fluid pressure extends
the overdrive piston, the piston contacts the direct clutch hub pressing it rearward. This action com
presses the direct clutch spring relieving spring load on the clutch pack. The clutch is disengaged once
spring load is relieved.
The 3-4 accumulator cushions overdrive clutch en
gagement to smooth the transition into fourth gear.
The accumulator is charged at the same time as ap
ply pressure acts against the overdrive piston.
Converter clutch engagement in overdrive fourth
gear is controlled by sensor inputs to the powertrain
control module. In third gear above 25 mph, sensor inputs to the control module that determine clutch
engagement and shift timing are:
• coolant temperature (verifies minimum of 60° F)
• engine speed • vehicle speed
• throttle position
• manifold vacuum (MAP sensor)
Gearshift
Mechanism
The gear shift mechanism provides the same shift
positions used with 3-speed Chrysler transmissions
(P-R-N-D-2-1).
The shift into overdrive fourth gear range occurs
only after the transmission has completed the shift into D third gear range. No further movement of the
shift mechanism is required to complete the 3-4 shift.
The fourth gear upshift occurs automatically when
the overdrive control switch is in the ON position. Shift timing is determined by sensor inputs to the
engine controller.
Overdrive Control
Switch
The overdrive control switch is located in the in
strument panel. In the On position, automatic shifts
into fourth gear overdrive will occur. In the Off posi
tion, the switch overrides the engine controller pre
venting a shift to overdrive fourth gear range.
The switch has an indicator light that illuminates
when overdrive is turned off. The switch also resets
when the ignition key is turned to the OFF position so that the automatic overdrive feature is restored.
The use of fault codes is employed to help diagnose
the electronic components that operate the overdrive
unit and converter clutch.
HYDRAULIC
CONTROLS
The 42REJ/46RH hydraulic control system provides
fully automatic operation. The system performs five
basic functions which are: pressure supply, pressure regulation, flow control, clutch/band application, and
lubrication. 42RH/46RH system operation is similar to that de
scribed in the 32RH/36RH/37RH General Informa tion section. The main difference being fourth gear
operation which is covered here.
Pressure
Regulation
The pressure regulator valve maintains line pres
sure.
The amount of pressure developed is controlled
by throttle pressure which is dependent on the de gree of throttle opening. The regulator valve is lo
cated in the valve body.
The throttle valve determines line pressure and
shift speed. Governor pressure increases in propor
tion to vehicle speed. The throttle valve controls up shift and downshift speeds by regulating pressure
according to throttle position.
Flow
Control And Lubrication The manual valve is operated by the gearshift link
age and provides the operating range selected by the
driver.
The 1-2 shift valve provides 1-2 or 2-1 shifts and
the 2-3 shift valve provides 2-3 or 3-2 shifts.
The kickdown valve provides forced 3-2 or 3-1
downshifts depending on vehicle speed. Downshifts
occur when the throttle is opened beyond downshift
detent position which is just before wide open throt
tle.
The 2-3 valve throttle pressure plug provides 3-2
downshifts at varying throttle openings depending on
vehicle speed.
The 1-2 shift control valve transmits 1-2 shift pres
sure to the accumulator piston. This controls kick-
down band capacity on 1-2 upshifts and 3-2 downshifts.
The 3-4 shift valve, shuttle valve, timing valve and
accumulator are only actuated when the overdrive
solenoid is energized.
The solenoid contains a check ball that controls a
vent port to the 3-4 valve. The check ball either di
verts line pressure away from or directly to, the 3-4 shift valve. Energizing the solenoid causes the check
ball to close the vent port allowing line pressure to act upon the 3-4 upshift valve.
The limit valve determines maximum speed at
which a 3-2 part throttle kickdown can be made. Some transmissions do not have the limit valve and
maximum speed for a 3-2 kickdown is at the detent
position.
The 2-3 shuttle valve has two functions. First is
fast front band release and smooth engagement dur ing lift-foot 2-3 upshifts. The second is to regulate
front clutch and band application during 3-2 down
shifts.
The 3-4 shuttle valve uses a combination of throt
tle and governor pressure to control the rate of over
drive piston apply and release. This is done to
maintain shift quality at varying throttle openings.

21 - 86
AUTOMATIC
TRANSMISSION-32RH/36RH/37RH/42RH/46RH
•
(6)
Remove dipstick and check fluid
level
as fol
lows:
(a) Dipstick has three fluid level indicating
marks which are a MIN dot mark, an OK mark and a MAX fill arrow mark:
(b) Correct level is to MAX arrow nark on dip
stick. This is correct maximum hot fluid level. Ac
ceptable level is between OK mark and max arrow
mark on dipstick.
(c) If level is at, or below MIN level dot on dip
stick, add only enough fluid to restore correct level.
Mopar ATF Plus, type 7176 is the preferred fluid.
Mopar Dexron II can be used if ATF Plus is not
readily available.
CAUTION:
Do not
overfill
the
transmission.
Overfill
ing
may
cause
leakage out the
pump
vent which
can
be mistaken for a
pump
seal
leak. In addition,
overfilling
will
also
cause
fluid
aeration
and
foam
ing
as the
excess
fluid is picked up and churned by
the
gear
train.
This
will
significantly
reduce fluid
life.
(7) Check and note fluid condition as follows: (a) Fluid should be dark to light red in color and
free of particles and sludge.
(b) If fluid is orange, brown, or smells slightly
burned, flow test and reverse flush cooler and lines. Then change fluid and filter and road test again to
confirm proper operation.
(c) If fluid is black, dark brown, turned to sludge,
contains extensive amount of metal or friction ma
terial particles, transmission will need overhaul. Main and auxiliary coolers will have to be flow
tested and reverse flushed as well.
Effects
Of Incorrect Fluid Level A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn
the fluid into foam, aerating the fluid and causing
the same conditions that occur with a low level.
In either case, air bubbles cause fluid overheating,
oxidation and varnish buildup which interferes with
valve, clutch and servo operation. Foaming also causes fluid expansion which can result in fluid over
flow from the transmission vent or fill tube. Fluid
overflow can easily be mistaken for a leak if inspec
tion is not careful.
FLUID
CONTAMINATION
Transmission fluid contamination is generally a re
sult of:
• adding incorrect fluid
• failure to clean dipstick and fill tube when check ing level
• engine coolant entering the fluid • internal failure that generates debris
• overheat that generates sludge (fluid breakdown)
• failure to reverse flush cooler and lines after re
pair
• failure to replace contaminated converter after re
pair
The use of non recommended fluids can result in
transmission failure. The usual results are erratic
shifts,
slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw ing the dipstick.
Engine coolant in the transmission fluid is gener
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission for some time, an overhaul may also be necessary; especially if shift problems
had developed.
The transmission cooler and lines should be reverse
flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be re
placed at the same time.
Failure to flush the cooler and lines will result in
re-contamination and a shop comeback. Flushing ap
plies to auxiliary coolers as well. The torque con verter should also be replaced whenever a failure
generates sludge and debris. This is necessary be
cause normal converter flushing procedures will not
remove al of the contaminants.
OVERDRIVE
FOURTH
GEAR
ELECTRICAL
CONTROLS
The electrical controls governing the shift into
fourth gear consist of the control switch on the in strument panel and the overdrive solenoid on the
valve body. The control switch is in circuit with the solenoid and must be in the On position to energize
the solenoid. The transmission must also have
reached third gear range before the shift to fourth gear will occur. The control switch, valve body solenoid, case con
nectors and related wiring can all be tested with a 12
volt test lamp or a multimeter. Check continuity of each component when diagnosis indicates this is nec
essary. Switch and solejioid continuity should be checked
whenever the transmission fails to shift into fourth
gear range.
THROTTLE
VALVE
CABLE
Throttle valve cable adjustment is important to
proper operation. This adjustment positions the

AUTOMATIC
TRANSMISSION—32RH/36RH/37RH/42RH/46RH
21 - 91
TEST
CONDITION
Line pressure OK during
any one test
Line Pressure OK in
R
but low in D, 2, 1
Pressure Low in D
Fourth Gear Range
Pressure OK in 1, 2 but
low
in
D3
and
R
Pressure OK in 2 but low in
R
and 1
Front servo pressure low
in 2
Pressure low in all positions
Governor pressure too high
at idle speed
Governor pressure low
at all mph figures Lubrication pressure low at
all throttle positions
INDICATION
Pump and regulator valve OK
Leakage in rear clutch area (servo,
clutch seals, governor support seal rings)
Overdrive clutch piston seal, or
check ball problem
Leakage in front clutch area (servo,
clutch seals, retainer bore, pump seal rings)
Leakage in rear servo
Leakage in servo; broken servo
ring or cracked servo piston
Clogged filter, stuck regulator
valve, worn or faulty pump, plugged fluid cooler
Governor valve sticking open
Governor valve sticking closed
Clogged oil cooler or lines, seal rings leaking, output shaft plugged
with debris, worn bushings in pump or clutch retainer
J9321-165
Fig.
7
Pressure
Test
Analysis
Chart (42RH/46RH)
STALL
TEST
DIAGNOSIS
Stall
Speed
Too
High
If stall speed exceeds specifications by more than
200 rpm, transmission clutch slippage is indicated.
Stall
Speed
Too Low Low stall speeds with a properly tuned engine in
dicate a torque converter overrunning clutch prob
lem. The condition should be confirmed by road
testing prior to converter replacement. The converter overrunning clutch is slipping when:
Stall speeds are 250 to 350 rpm below specified min
imum and the vehicle operates properly at highway
speeds but has poor low speed acceleration.
Stall
Speed
Normal
If stall speeds are normal but abnormal throttle
opening is required to maintain highway speeds, the
converter overrunning clutch is seized and the torque
converter must be replaced.
Converter
Noise
During
Test
A whining noise caused by fluid flow is normal
during a stall test. However, loud metallic noises in dicate a damaged converter. To confirm that noise is
originating from the converter, operate the vehicle at
light throttle in Drive and Neutral on a hoist and
lis
ten for noise coming from the converter housing.
AIR
TESTING
CLUTCH
AND
BAND
OPERATION
Air pressure testing can be used to check clutch
and band operation with the transmission either in
the vehicle, or on the work bench as a final check af
ter overhaul. Air pressure testing requires that the oil pan and
valve body be removed from the transmission. The servo and clutch apply passages are shown in Figure
8.
FRONT
SERVO
APPLY^
REAR
SERVO
APPLY
LINE
PRESSURE
TO
ACCUMULATOR
GOVERNOR
PRESSURE
FRONT
SERVO
RELEASE
PUMP
SUCTION
PUMP
PRESSURE
FRONT
CLUTCH
APPLY
REAR
CLUTCH
APPLY
TO
TORQUE
CONVERTOR
I
FROM
TORQUE
CONVERTER
TO
GOVERNOR
TO
COOLER
^H252
Fig.
8 Air
Pressure
Test
Passages
Front
Clutch
Test
Place one or two fingers on the clutch housing and
apply air pressure through front clutch apply passage (Fig. 8). Piston movement can be felt and a soft thud
heard as the clutch applies.
Rear
Clutch
Test
Place one or two fingers on the clutch housing and
apply air pressure through rear clutch apply passage
(Fig. 8). Piston movement can be felt and a soft thud
heard as the clutch applies.
Front
Servo
Test
Apply air pressure to the front servo apply passage.
The servo rod should extend and cause the band to
tighten around the drum. Spring tension should re lease the servo when air pressure is removed.