Dodge Ram Truck 1500-2500-3500. Manual — part 1788

3. Remove overrunning clutch assembly (1) with

expanding type snap-ring pliers. Insert pliers into
clutch hub. Expand pliers to grip hub splines and
remove

clutch

with

counterclockwise,

twisting

motion.

4. Remove thrust bearing from overrunning clutch

hub.

5. Remove overrunning clutch from hub.

6. Mark position of annulus gear and direct clutch

drum (1) for assembly alignment reference. Use
small center punch (3) or scriber to make align-
ment marks.

7. Remove direct clutch drum (2) rear retaining ring

(1).

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8. Remove direct clutch drum outer retaining ring (1).

9. Mark annulus gear and output shaft (1) for assem-

bly alignment reference. Use punch (3) or scriber
to mark gear and shaft.

10. Remove snap-ring (3) that secures annulus gear

(2) on output shaft (1). Use two screwdrivers to
unseat and work snap-ring out of groove as
shown.

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11. Remove annulus gear (2) from output shaft (1).

Use rawhide or plastic mallet to tap gear off shaft.

GEAR CASE AND PARK LOCK

1. Remove locating ring from gear case.

2. Remove park pawl shaft retaining bolt and remove shaft, pawl and spring.

3. Remove reaction plug snap-ring and remove reaction plug.

4. Remove output shaft seal.

CLEANING

Clean the geartrain and case components with solvent. Dry all parts except the bearings with compressed air. Allow
bearings to air dry.

Do not use shop towels for wiping parts dry unless the towels are made from a lint-free material. A sufficient quan-
tity of lint (from shop towels, cloths, rags, etc.) could plug the transmission filter and fluid passages.

Discard the old case gasket and seals. Do not attempt to salvage these parts. They are not reusable. Replace any
of the overdrive unit snap-rings if distorted or damaged.

Minor nicks or scratches on components can be smoothed with crocus cloth. However, do not attempt to reduce
severe scoring on any components with abrasive materials. Replace severely scored components; do not try to
salvage them.

INSPECTION

Check condition of the park lock components and the overdrive case.

Check the bushings in the overdrive case. Replace the bushings if severely scored or worn. Also replace the case
seal if loose, distorted, or damaged.

Examine the overdrive and direct clutch discs and plates. Replace the discs if the facing is worn, severely scored,
or burned and flaking off. Replace the clutch plates if worn, heavily scored, or cracked. Check the lugs on the clutch
plates for wear. The plates should slide freely in the drum. Replace the plates or drum if binding occurs.

Check condition of the annulus gear, direct clutch hub, clutch drum and clutch spring. Replace the gear, hub and
drum if worn or damaged. Replace the spring if collapsed, distorted, or cracked.

Be sure the splines and lugs on the gear, drum and hub are in good condition. The clutch plates and discs should
slide freely in these components.

Inspect the thrust bearings and spring plate. Replace the plate if worn or scored. Replace the bearings if rough,
noisy, brinnelled, or worn.

Inspect the planetary gear assembly and the sun gear and bushings. If either the sun gear or the bushings are
damaged, replace the gear and bushings as an assembly. The gear and bushings are not serviced separately.

The planetary carrier and pinions must be in good condition. Also be sure the pinion pins are secure and in good
condition. Replace the carrier if worn or damaged.

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Inspect the overrunning clutch and race. The race surface should be smooth and free of scores. Replace the over-
running clutch assembly or the race if either assembly is worn or damaged in any way.

Replace the shaft pilot bushing and inner bushing if damaged. Replace either shaft bearing if rough or noisy.
Replace the bearing snap-rings if distorted or cracked.

Check the machined surfaces on the output shaft. These surfaces should clean and smooth. Very minor nicks or
scratches can be smoothed with crocus cloth. Replace the shaft if worn, scored or damaged in any way.

Inspect the output shaft bushings. The small bushing is the intermediate shaft pilot bushing. The large bushing is the
overrunning clutch hub bushing. Replace either bushing if scored, pitted, cracked, or worn.

ASSEMBLY

GEARTRAIN AND DIRECT CLUTCH

1. Soak direct clutch and overdrive clutch discs in

Mopar

T

ATF +4, Automatic Transmission fluid.

Allow discs to soak for 10-20 minutes.

2. Install annulus gear (3) on output shaft, if removed.

Then install annulus gear retaining snap-ring (1).

3. Align and install clutch drum (3) on annulus gear

(1). Be sure drum is engaged in annulus gear lugs.

4. Install clutch drum outer retaining ring (2).

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