42RLE Automatic Transmission (Service Information): Assembly: Assembly
NOTE:
If the transmission assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Transmission Control - Standard Procedure
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| 1 - THRUST BEARING NO. 1 | 5 - THRUST BEARING NO. 5 |
| 2 - THRUST BEARING NO. 2 | 6 - NEEDLE BEARING NO. 6 |
| 3 - THRUST BEARING NO. 3 | 7 - NEEDLE BEARING NO. 7 |
| 4 - THRUST BEARING NO. 4 | - |
- Install the output bearing cups using Installer 5050A.
1 - GASKET HOLES MUST LINE UP 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET - Install low/reverse piston retainer gasket (2)
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1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - GASKET - Install low/reverse piston retainer (1)
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1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - SCREWDRIVER 3 - TORX-LOC SCREWS - Install low/reverse piston retainer-to-case screws (3)
and torque to 5 N.m (45 in. lbs.).
1 - LOW/REVERSE CLUTCH PISTON 2 - D-RING SEAL 3 - D-RING SEAL NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly. - Install low/reverse clutch piston (1)
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1 - GUIDE BRACKET 2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN) 3 - PAWL - Assemble guide bracket (1)
assembly as shown in illustration, if necessary.
1 - PIVOT PIN 2 - GUIDE BRACKET ASSEMBLY CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case. - Install guide bracket pivot pin (1) .
- Install park sprag pivot retaining screw and torque to 4.5 N.m (40 in. lbs.).
1 - LOW/REVERSE PISTON RETURN SPRING 2 - PISTON - Install low/reverse piston Belleville spring (1) into position.
1 - LOW/REVERSE CLUTCH RETURN SPRING 2 - SNAP RING (INSTALL AS SHOWN) 3 - COMPRESSOR 5058A-3 4 - COMPRESSOR 5059-A 5 - DISC 6057 - Install and load low/reverse spring with compressor tool 5058A-3 (3), 5059-A (4) and disc 6057 (5) as shown in illustration
to facilitate snap ring (2) installation.
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN) 2 - SNAP RING PLIERS 3 - DISC 6057 - Install snap ring (1) and remove compressor tool.
1 - ARBOR PRESS 2 - UNIVERSAL HANDLE C-4171 3 - INSTALLER 6052 4 - REAR CARRIER - Install rear carrier (4) front bearing cone.
1 - SUPPORT PLATE 6618A 2 - REAR OUTPUT SHAFT BEARING Check output bearing preload. Output bearing preload must be checked and/or adjusted if any of the following items have been replaced:
- Output shaft (rear carrier assembly)
- Output shaft bearings
- Transmission case
- PRELOAD CHECK/SHIM SELECTION:
Install rear output shaft bearing cone and Support Plate 6618A (1)
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1 - SUPPORT PLATE 6618A - Install Support Plate 6618A (1) . Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
- Turn case over on arbor press so that the plate is resting on the press base. CAUTION: The output shaft will extend through the hole of Support Plate 6618A. Ensure your press table has clearance for the output shaft.
1 - SHIM 2 - OUTPUT SHAFT - Install shim (1) on output shaft (2)
. Apply small amount of petrolatum onto the shim to hold it in place. Use the original shim as a starting point. If original shim is not available, use the thickest shim available.
1 - UNIVERSAL HANDLE C-4171 AND HANDLE EXTENSION C-4171-2 2 - DISC MD-998911 - Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use Disc MD-998911 (2)
and Universal Handle C- 4171 and Handle Extension C4171-2 (1) to press shaft into rear bearing.
1 - TORQUE WRENCH 2 - WRENCH 6498A 3 - OUTPUT SHAFT NUT CAUTION: Do not reuse old output shaft nut because the removed stake weakens the nut flange. Using Wrenches 6497 and 6498A, install new output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.). - Check the turning torque (1) of the output shaft
. The shaft should have 1 to 8 in. lbs. of turning torque. If the turning torque is higher than
8 in. lbs., install a thicker shim. If turning torque is less than
1 in. lb., install a thinner shim. Make sure there is no end play.
1 - ARBOR PRESS 2 - STAKING TOOL - 6639 3 - NEW NUT CAUTION: Failure to stake nut could allow the nut to back-off during use. - The new nut (3) must be staked after the correct turning torque is obtained
. Use Staking Tool 6639 (2) to stake output shaft nut.
1 - BOTTOMED IN SLOT 2 - CORRECTLY STAKED NUT - Verify that the nut has been properly staked
to the output shaft.
1 - CLUTCH PLATES (5) 2 - CLUTCH DISCS (5) - Install low/reverse clutch pack (1, 2)
. Leave uppermost disc out to facilitate snap ring installation.
1 - SCREWDRIVER 2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING 3 - DO NOT SCRATCH CLUTCH PLATE - Install low/reverse reaction plate snap ring (2)
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1 - ONE DISC FROM LOW/REVERSE CLUTCH - Install one low/reverse clutch disc (1)
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP) - Install low/reverse reaction plate (1) with flat side up.
1 - SCREWDRIVER 2 - TAPERED SNAP RING (INSTALL AS SHOWN) - Install a new tapered snap ring (2) (tapered side out).
- Make sure that the snap ring ends
are oriented as shown in illustration.
1 - DIAL INDICATOR 2 - DIAL INDICATOR TIP TOOL 6268 3 - HOOK TOOL - Measure low/reverse clutch pack. Set up dial indicator (1) as shown in illustration. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. Low/Reverse clutch pack clearance is 0.84 to 1.60 mm (0.033 to 0.063 inch).
- Select the proper low/reverse reaction plate to achieve specifications.
1 - CLUTCH PLATE (4) 2 - CLUTCH DISC (4) - Install 2/4 clutch pack (1, 2)
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1 - 2/4 CLUTCH RETURN SPRING NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly. - Install 2/4 clutch Belleville spring (1)
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1 - NOTE POSITION 2 - RETURN SPRING 3 - 2/4 CLUTCH RETAINER - Verify the proper orientation of the return spring (2)
to the 2/4 retainer (3).
1 - 2/4 CLUTCH RETAINER - Install 2/4 clutch retainer (1)
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1 - TOOL 5058A 2 - SCREWDRIVER 3 - SNAP RING 4 - 2/4 CLUTCH RETAINER NOTE: Verify that Compressor 5058A (1) is centered properly over the 2/4 clutch retainer (4) before compressing. If necessary, fasten the bar from Compressor 5058A to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly. - Set up Compressor 5058A (1)
as shown in illustration. Compress 2/4 clutch just enough to facilitate snap ring installation.
1 - DIAL INDICATOR 2 - HOOK TOOL 3 - DIAL INDICATOR TIP TOOL 6268 - Measure 2/4 clutch clearance:
Set up dial indicator (1)
as shown in illustration. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to 0.104 inch).
If not within specifications, the clutch is not assembled properly or is excessively worn. There is no adjustment for the 2/4 clutch clearance.
1 - #7 BEARING 2 - REAR SUN GEAR - Install the #7 needle bearing (1) to the rear sun gear (2)
. The number 7 needle bearing has three anti-reversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
1 - #7 NEEDLE BEARING 2 - REAR SUN GEAR - Install rear sun gear (2) and #7 needle bearing (1)
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1 - #6 NEEDLE BEARING 2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL). - Install front carrier/rear annulus assembly (2) and #6 needle bearing (1)
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1 - FRONT SUN GEAR ASSEMBLY 2 - #4 THRUST WASHER (FOUR TABS) - Install front sun gear assembly (1) and #4 thrust washer (2)
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1 - OVERDRIVE SHAFT ASSEMBLY 2 - #4 THRUST PLATE (SELECT) 3 - PETROLATUM FOR RETENTION - Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate.
- Install #4 thrust plate (2) using petrolatum to hold into position.
- Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole. If the speed sensor tone wheel is not centered in the opening, the input clutches assembly is not seated properly.
1 - OIL PUMP ASSEMBLY 2 - O-RING - Remove the oil pump o-ring (2)
and install oil pump and gasket to transmission. Use screw-in dowels or Phillips head screwdrivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.
1 - TOOL 8266-8 2 - TOOL 8266-2 3 - TOOL C-3339A - Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate.
- Set up and measure endplay using End Play Set 8266A (1, 2) and Dial Indicator Set C3339A (3) as shown in illustration.
- Measure input shaft end play. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch).
For example, if end play reading is 0.055 inch, select No. 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch, which is within specifications.
1 - INPUT CLUTCH ASSEMBLY - Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
- Install input clutch assembly (1) with proper thrust plate
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1 - #1 CAGED NEEDLE BEARING 2 - NOTE: TANGED SIDE OUT - Install #1 caged needle bearing (1)
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1 - BYPASS VALVE CAUTION: By-pass valve MUST be replaced if transmission failure occurs. - Replace cooler by-pass valve (1)
if transmission failure has occurred.NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or Phillips screwdrivers.
1 - BELLHOUSING 2 - OIL PUMP GASKET - Install oil pump gasket (2)
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1 - BOLTS 2 - OIL PUMP - Install oil pump (2)
and torque oil pump-to-case bolts (1) to 30 N.m (265 in. lbs.). Do not reuse original oil pump bolts.
1 - ACCUMULATOR PISTON - Install low/reverse accumulator (1)
as shown in illustration.
1 - ADJUSTABLE PLIERS 2 - PLUG - Install low/reverse accumulator plug (2)
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1 - SNAP RING 2 - LOW/REVERSE ACCUMULATOR - Install low/reverse accumulator snap ring (1)
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1 - OVERDRIVE PISTON AND SPRING 2 - UNDERDRIVE PISTON AND SPRING - Install underdrive (2) and overdrive (1) accumulators and springs
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1 - VALVE BODY CAUTION: Do not handle the valve body by the manual shaft. Damage could result. - Install valve body (1)
into place as shown in illustration.
1 - BOLTS - Install seven (7) valve body-to-case bolts (1)
and torque to 12 N.m (105 in. lbs.).
1 - TRANSMISSION FILTER - Install transmission oil filter (1)
. Tighten the bolts to 5 N.m (45 in. lbs.).
1 - TRANSMISSION OIL PAN - Install transmission oil pan (1)
with a bead of Mopar® ATF RTV.
1 - FRONT DRIVESHAFT 2 - PRESSURE PORTS 3 - TRANSMISSION CASE 4 - TRANSMISSION OIL PAN 5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE 6 - FIRST TRANSMISSION OIL PAN BOLT NOTE: Before installing the oil pan bolt in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits , it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock AND Seal Adhesive. - Install and torque the oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.).
1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - TRANSMISSION RANGE SENSOR NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock AND Seal Adhesive. - Install both speed sensors (1, 2)
into the transmission case. Torque the speed sensor bolts to 9 N.m (80 in. lbs.).
1 - TOOL 8266-8 2 - TOOL 8266-2 3 - TOOL C-3339A - As a final check of the transmission, measure the input shaft end play. This will indicate when a #4 thrust plate change is required. The #4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator C-3339A to transmission bell housing with its plunger seated against end of input shaft . Install tool 8266-2 (2), 8266-8 (1) and move input shaft in and out to obtain end play reading. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). If not within specifications, make the necessary thrust plate adjustment.
- On 4X2 transmissions, perform the following, if necessary:
- Install the extension shaft bearing (2)
onto the extension shaft.
1 - EXTENSION SHAFT 2 - BEARING - Install the extension shaft bearing retaining ring (3)
onto the extension shaft (1).
1 - EXTENSION SHAFT 2 - BEARING 3 - RETAINING RING - Install the extension shaft (2) and bearing assembly (3)
into the extension housing (1).
1 - EXTENSION HOUSING 2 - EXTENSION SHAFT 3 - BEARING - Install the extension shaft bearing snap ring (3)
into the extension housing.
1 - EXTENSION SHAFT 2 - BEARING 3 - SNAP RING - Verify that the extension shaft snap ring (3)
is fully engaged in the snap ring groove.
1 - EXTENSION SHAFT 2 - BEARING 3 - SNAP RING
1 - HOUSING 2 - LUBE TUBE 3 - GROMMET 4 - PRY SLOTS - Install the extension shaft bearing (2)
onto the extension shaft.
- Inspect the lube tube grommet (2)
for damage. If the grommet lip is damaged, it will need to be replaced.
1 - TRANSMISSION CASE 2 - ADAPTER HOUSING - Install the 4X4 stub shaft onto the transmission output shaft.
- Place a bead of Mopar® ATF RTV on the rear surface of the transmission case for the adapter/extension housing.
- Install the adapter
housing (2) onto the transmission case, 4X4 vehicles only.
1 - TRANSMISSION CASE 2 - EXTENSION HOUSING - Install the extension
housing (2) onto the transmission case, 4X2 vehicles only.
1 - STUD, ADAPTER/EXTENSION 2 - TRANSMISSION MOUNT FASTENERS (4) 3 - TRANSMISSION MOUNT 4 - TRANSMISSION CASE 5 - NUT, EXHAUST HANGER BRACKET (2) 6 - STUD, ADAPTER/EXTENSION 7 - TRANSMISSION OIL PAN 8 - BOLT, ADAPTER/EXTENSION (2) NOTE: Before installing the lowermost four adapter/extension housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mopar® Lock AND Seal Adhesive.1 - TRANSMISSION CASE 2 - ADAPTER HOUSING 3 - BOLTS - Install the bolts that hold the adapter or extension housing onto the transmission case. Be sure to install any stud bolts to their original locations. Tighten the bolts to 54 N.m (40 ft. lbs.).