Section 318 (42RLE Automatic Transmission (Service Information)): Disassembly: Disassembly

WARNING: This page is about a different car, the 2010 Dodge Charger and 2010 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the transmission 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/MODULE, Transmission Control - Standard Procedure .

NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.

CAUTION: Do not intermix clutch discs or plates as the unit might then fail.

Before disassembling transmission, move the shift lever clockwise as far as it will go and then remove the shift lever.

Fig 1: Removing/Installing Torque Converter

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1 - TORQUE CONVERTER

2 - TRANSMISSION

3 - INPUT SHAFT

Remove the torque converter (1) from the transmission input shaft (3).

Fig 2: Measure Input Shaft End Play Using Tool 8266A - Typical

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339A

Measure input shaft end play using End Play Set 8266A (1, 2). Set up End Play Set 8266A and a dial indicator as shown in illustration.
Move input shaft in and out to obtain end play reading. End play specifications are 0.13 to 0.64 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transmission. If endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.

Fig 3: Removing/Installing Rear Output Shaft Retaining Ring
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1 - RETAINING RING

2 - OUTPUT SHAFT BEARING

NOTE: It is not necessary to remove the output shaft flange to disassemble the transmission. Perform the following steps only if it necessary to replace a component in the extension housing assembly.
Place the transmission in PARK to prepare for the removal of the output shaft nut.
Remove the nut holding the propeller shaft flange to the output shaft and remove the flange.
Remove the transmission rear oil seal with a suitable slide hammer and screw.
Remove the transmission output shaft washer.

Remove the transmission rear output shaft bearing retaining ring (1).

Fig 4: Position Remover 9082A On Bearing

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1 - BEARING REMOVER 9082A

2 - TRANSMISSION CASE

3 - OUTPUT SHAFT BEARING

Position Bearing Remover 9082A (1) over the inner race of the output shaft bearing (3).

Fig 5: Slide Remover 9082A Collar Downward

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1 - BEARING REMOVER 9082A

2 - TRANSMISSION CASE

3 - COLLAR

4 - FINGERS

NOTE: Due to production variations in the bearing, it may not be possible to slide the collar fully downward. It is only necessary to slide the collar down far enough that the fingers securely grasp the inner bearing race.

Slide the collar (3) on the Bearing Remover 9082A (1) downward over the fingers (4) of the tool.

Fig 6: Removing/Installing Output Shaft Bearing

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1 - BEARING REMOVER 9082A

2 - TRANSMISSION CASE

3 - OUTPUT SHAFT BEARING

Remove the output shaft bearing (3) .
Remove the geartrain end-play shim from the output shaft. Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged.

Fig 7: Removing/Installing Adapter/Extension Housing Bolts
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NOTE: The four bolts (3) along the bottom of the extension housing (2) have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.
Remove the bolts that hold the extension housing (2) onto the transmission case.

Fig 8: Remove/Install Extension Housing
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Remove the extension (2) housing from the transmission case. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.

Fig 9: Housing, Lube Tube, Grommet & Pry Slots

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1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

Inspect the lube tube grommet (3) for damage. If the grommet lip is damaged, it will need to be replaced.

Fig 10: Removing/Installing Input Speed Sensor Bolt
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1 - INPUT SPEED SENSOR

2 - TRANSMISSION CASE

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
Remove the input speed sensor bolt.

Fig 11: Removing/Installing Output Speed Sensor Bolt
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
Remove the output speed sensor bolt.

Fig 12: Removing/Installing Output Speed Sensor
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the input and output (2) speed sensors. Identify the speed sensors for re-installation since they are not interchangeable.

Fig 13: Removing/Installing Transmission Oil Pan Bolts
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1 - TRANSMISSION OIL PAN

2 - BOLTS

NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.
Remove the transmission oil pan bolts (2) .

Fig 14: Removing/Installing Transmission Oil Pan
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1 - TRANSMISSION OIL PAN
Remove the transmission oil pan (1) .

Fig 15: Removing/Installing Oil Filter Screws
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1 - OIL FILTER

2 - SCREWS
Remove the transmission oil filter screws (2) .

Fig 16: Removing/Installing Transmission Filter
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1 - TRANSMISSION FILTER
Remove transmission oil filter (1) .

Fig 17: Removing/Installing Oil Filter O-Ring
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1 - VALVE BODY

2 - O-RING
Remove the oil filter o-ring (2) from the valve body.
If necessary, use a suitable tool to push the transmission fill tube grommet and extension from the transmission case from the bottom.

Fig 18: Removing/Installing Valve Body Bolts
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1 - BOLTS
Remove valve body-to-case bolts (1) .

Fig 19: Removing/Installing Valve Body
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1 - VALVE BODY

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Remove valve body (1) from transmission.

Fig 20: Identifying Underdrive and Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Remove underdrive and overdrive accumulators (1, 2) .

Fig 21: Remove/Install Low/Reverse Accumulator & Snap Ring
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Remove the low/reverse accumulator snap ring (1) .

Fig 22: Removing/Installing Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Remove the low/reverse accumulator plug (2) .

Fig 23: Identifying Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON
Remove low/reverse accumulator piston (1) using suitable pliers.

Fig 24: Low/Reverse Accumulator
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1 - PISTON

2 - RETURN SPRINGS
Remove piston (1) and springs (2) .

Fig 25: Remove/Install Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP
Remove and discard the oil pump-to-case bolts (1) . The oil pump bolts are not to be reused.

Fig 26: Oil Pump Pullers
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1 - OIL PUMP

2 - PULLERS
Remove oil pump using C-3752 Pullers (2) .

Fig 27: Removing/Installing Oil Pump
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
Remove oil pump while pushing in on input shaft (1) .

Fig 28: Removing/Installing Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Remove oil pump gasket (2) .

Fig 29: Remove/Install By-Pass Valve
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1 - BYPASS VALVE

CAUTION: By-pass valve must be replaced if transmission failure occurs.
Remove the cooler by-pass valve (1) .

Fig 30: Removing/Installing No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove the #1 caged needle bearing (1) .

Fig 31: Removing/Installing Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY

Remove the input clutch assembly (1) .

Fig 32: Removing/Installing #4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Remove the #4 thrust plate (2) .

Fig 33: Removing/Installing Front Sun Gear Assembly
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Remove the front sun gear assembly (1) and #4 thrust washer (if still in place).

Fig 34: Removing/Installing Front Carrier/Rear Annulus

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1 - #6 NEEDLE BEARING

2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

Remove the front carrier/rear annulus (2) and #6 needle bearing (1) .

Fig 35: Removing/Installing Rear Sun Gear
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Remove the rear sun gear (2) and #7 needle bearing (1) .

Fig 36: Remove/Install Rear Sun Gear & No. 7 Bearing

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1 - #7 BEARING

2 - REAR SUN GEAR

NOTE: The number seven needle bearing (1) has three antireversal tabs and is common with the number five and number two 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.

Fig 37: Removing/Installing 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE: Verify that Compressor Tool 5058A (1) is centered properly over the 2/4 clutch retainer (4) before compressing. If necessary, fasten the Compressor Tool 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Install and load Tool 5058A to remove the 2/4 clutch retainer snap ring (3) .

Fig 38: 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

2 - 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.
Remove the 2/4 clutch retainer (1) .

Fig 39: Removing/Installing 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch return spring (1) .

Fig 40: Removing/Installing 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

Remove the 2/4 clutch pack (1, 2) .

Fig 41: Removing/Installing Tapered Snap Ring

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1 - LOW/REVERSE CLUTCH REACTION PLATE

2 - LONG TAB

3 - SCREWDRIVER

4 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)

5 - OIL PAN FACE

Remove the tapered snap ring (4) .

Fig 42: Removing/Installing Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove the low/reverse reaction plate (1) .

Fig 43: Removing/Installing One Low/Reverse Clutch Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove one (1) low/reverse clutch disc to facilitate snap ring removal.

Fig 44: Removing/Installing Low/Reverse Reaction Plate Snap Ring

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1 - SCREWDRIVER

2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

3 - DO NOT SCRATCH CLUTCH PLATE

Remove the low/reverse reaction plate snap ring (2) .

Fig 45: Removing/Installing Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Remove the low/reverse clutch pack (1, 2) .

Fig 46: Grinding Stakes

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1 - OUTPUT SHAFT

2 - GRIND HERE

3 - GRIND HERE

4 - NUT STAKE

CAUTION: Failure to grind and open stakes (4) of the output shaft nut will result in thread damage to the shaft during nut removal.

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.

Fig 47: Stake Grinding Pattern

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1 - OUTPUT SHAFT

2 - OUTPUT SHAFT NUT

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut (2) as shown in illustration. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Fig 48: Opening Nut Stakes
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1 - CHISEL

2 - NUT STAKE

Using a small chisel (1), carefully open the stakes on nut (2) .

Fig 49: Removing/Installing Output Shaft Nut

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1 - SPECIAL TOOL 6497

2 - SPECIAL TOOL 6498A

3 - BREAKER BAR

Remove snap ring from output shaft.

Use Wrench 6497 (1) and 6498A (2) to remove the output shaft nut.

Fig 50: Use Arbor Press to Remove Output Shaft from Case

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1 - OUTPUT SHAFT

2 - ARBOR PRESS

3 - TRANSMISSION CASE

Remove the output shaft (1) from case (3) using a shop press (2).

Fig 51: Removing/Installing Front Bearing Cup - Typical
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1 - ARBOR PRESS

2 - SPECIAL TOOL 6596
Use Remover 6596 (2) with a shop press (1) to remove the front output shaft bearing cup.

Fig 52: Removing/Installing Rear Bearing Cup
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1 - SPECIAL TOOL 4171 AND 4171-2

2 - SPECIAL TOOL 6597

Use Wrench 6597 (2) and handle C-4171 (1) and C-4171-2 to press the rear output shaft bearing cup rearward.

Fig 53: Removing/Installing Rear Carrier Front Bearing Cone

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1 - SPECIAL TOOL 5048-1

2 - SPECIAL TOOL 6545

3 - REAR CARRIER

4 - SPECIAL TOOL 5048

Remove the rear carrier front bearing cone (3) .

Fig 54: Compressor Tool in Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)

3 - TOOL 5058A-3

4 - TOOL 5059-A

5 - SPECIAL TOOL 6057

Install and load compressor 5059-A (4) as shown in illustration.

Fig 55: Removing/Installing Snap Ring

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1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION)

2 - SNAP RING PLIERS

3 - SPECIAL TOOL 5059-A

Remove the low/reverse belleville spring snap ring (1) .

Fig 56: Removing/Installing Low/Reverse Piston Return Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON
Remove the low/reverse piston belleville spring (1) .

Fig 57: Anchor Shaft Removal
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1 - PIN PUNCH

2 - GUIDE BRACKET ASSEMBLY
Remove the park sprag pivot retaining screw.
Drive out the anchor shaft using suitable punch (1) .

Fig 58: Removing/Installing Guide Bracket Pivot Shaft
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

Remove the guide bracket pivot pin (1) . Inspect all components for wear and replace if necessary.

Fig 59: Removing/Installing Low/Reverse Clutch Piston

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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.

Remove the low/reverse clutch piston (1) .
Remove the low/reverse piston retainer screws.

Fig 60: Removing/Installing Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer (1) .

Fig 61: Removing/Installing Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Remove the low/reverse piston retainer gasket (2) .