BLOWN AWAY. Remember the Dodge truck we. by High Pressure STREET SMART. by Mike Brown members.atra.com

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1 STREET SMART BLOWN AWAY by Mike Brown members.atra.com by High Pressure Figure 1 Remember the Dodge truck we talked about in the January 2015 issue? The 2003 Dodge Ram diesel? This is what happened to the front clutch (figure 1). The truck came in with the front clutch blown apart; the shop replaced the drum, only to blow the new drum apart while it was still on the lift. After replacing the valve body with a new, stock valve body, the pressure dropped down to where it belonged. I inspected the old valve body and found it was severely worn out, with pieces missing. Now we re looking at a 2005 Dodge Ram diesel with high line pressure; 110 PSI (760 kpa) at idle and PSI ( kpa) at stall. The pressure should only be PSI ( kpa) at idle, and stall should be no more than PSI ( kpa). So I sent a call tag to have the shop send the valve body to me for inspection. 26 GEARS May 2015

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3 Eliminate Valve Body Leaks by Flat Sanding Figure 2 Figure 3 Figure 4 After receiving the valve body and cleaning it up, I performed a complete set of vacuum checks: All the valves passed. The spring adjustment on the pressure regulator valve was 1 5/16 (33.3 mm) right where it belonged so what could be causing the high pressure? Since this valve body doesn t use any gaskets between the channel plate and the separator plate or the separator plate and the valve body, it s very important for the surfaces to be flat. To check the valve body for flatness, I used a piece of glass and a sheet of 220 wet/dry sandpaper. I wet the sandpaper with a mix of liquid dish Figure 5 To check the valve body for flatness, I used a piece of glass and a sheet of 220 wet/dry sandpaper. I wet the sandpaper with a mix of liquid dish soap and water, then I sanded each surface of the valve body. soap and water, then I sanded each surface of the valve body. I used a figure-eight motion, running each piece over the sandpaper lightly a few times. Then I checked the results. Here s what I found. Notice the uneven the surface across the upper valve body (figure 2). 28 GEARS May 2015

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5 Eliminate Valve Body Leaks by Flat Sanding Figure 6 Figure 7 Then I spent a little time flat sanding the valve body; look at the difference (figure 3). Next, I turned the upper valve body over and did the same thing. Look how bad the contact area was on this side (figure 4). Notice the area over the boost valve: That s a major leak! And the other side, where the shuttle valve cover plate goes; that s pretty bad too. Once again, a little time flat sanding and you can see the difference (figure 5). Now let s look at the part of the valve body where the governor plug plate goes (figure 6). That surface is really bad; and once again a little time flat sanding was all it took to flatten things out (figure 7). But wait! Look at where the limit valve housing goes (figure 8 & 9); another major leak. You get the idea: Every surface on the valve body was seriously warped. Kind of makes you wonder how it worked at all. I spent about an hour and a half flat sanding this valve body. Then I put it all back together and torqued the bolts to 35 in-lbs (about 4 Nm). I boxed it up and sent it back the shop it originally came from. They installed in the next Dodge truck that came in and checked the pressures. What do you know? The pressure at idle dropped from 110 PSI to 70 PSI (from 760 kpa to 485 kpa); still a little high but not unreasonable. The pressure at stall was PSI ( kpa); now it s PSI ( kpa). Wow! What a difference simply by flat sanding! So, if you take the time to vacuum test, flat sand, and torque your valve body to specs, you ll be able to look forward to more consistency in your rebuilds. And that s not just smart that s street smart! Figure 8 Figure 9 30 GEARS May 2015

6 LifeAuto_May2015.indd 1 4/29/15 12:49 PM

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