Automatic Transmission-42RE: Assembly

Do not allow dirt, grease, or foreign material to enter the case or transmission components during assembly. Keep the transmission case and components clean. Also make sure the tools and workbench area used for assembly operations are equally clean.

Shop towels used for wiping off tools and hands must be made from lint free  material. Lint will stick to transmission parts and could interfere with valve operation, or even restrict fluid passages.

Lubricate the transmission components with Mopar® transmission fluid during reassembly. Use Mopar® Door Ease, or Ru-Glyde™ on seals and O-rings to ease installation.

Petroleum jelly can also be used to hold thrust washers, thrust plates and gaskets in position during assembly. However, do not  use chassis grease, bearing grease, white grease, or similar lubricants on any transmission part. These types of lubricants can eventually block or restrict fluid passages and interfere with valve operation. Use petroleum jelly only.

Do not force parts into place. The transmission components and subassemblies are easily installed by hand when properly aligned.

If a part seems extremely difficult to install, it is either misaligned or incorrectly assembled. Also verify that thrust washers, thrust plates and seal rings are correctly positioned before assembly. These parts can interfere with proper assembly if mis-positioned.

The planetary geartrain, front/rear clutch assemblies and oil pump are all much easier to install when the transmission case is upright.

1. Install rear servo piston, spring and retainer (Fig 1). Install spring on top of servo piston and install retainer on top of spring.
   Fig 1: Identifying Rear Servo Components

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2. Install front servo piston assembly, servo spring and rod guide (Fig 2).
   Fig 2: Identifying Front Servo Components

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3. Compress front/rear servo springs with Valve Spring Compressor C-3422-B and install each servo snap-ring (Fig 3).
   Fig 3: Compressing Front/Rear Servo Springs

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4. Lubricate clutch cam rollers with transmission fluid.
5. Install rear band in case (Fig 4). Be sure twin lugs on band are seated against reaction pin.
   Fig 4: Installing Rear Band

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6. Install low-reverse drum and check overrunning clutch operation as follows:
   1. Lubricate overrunning clutch race (on drum hub) with transmission fluid.
   2. Guide drum through rear band.
   3. Tilt drum slightly and start race (on drum hub) into overrunning clutch rollers.
   4. Press drum rearward and turn it in clockwise direction until drum seats in overrunning clutch (Fig 5).
   5. Turn drum back and forth. Drum should rotate freely in clockwise direction and lock in counterclockwise direction (as viewed from front of case).
   Fig 5: Installing Low-Reverse Drum

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7. Install snap-ring that secures low-reverse drum to hub of overdrive piston retainer (Fig 6).
   Fig 6: Installing Low-Reverse Drum Retaining Snap-Ring

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8. Install rear band lever and pivot pin (Fig 7). Align lever with pin bores in case and push pivot pin into place.
   Fig 7: Installing Rear Band Lever And Pivot Pin

   Courtesy of DAIMLERCHRYSLER CORP.
9. Install planetary geartrain assembly (Fig 8).
   Fig 8: Installing Planetary Geartrain

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10. Install thrust plate on intermediate shaft hub (Fig 9). Use petroleum jelly to hold thrust plate in place.
    Fig 9: Installing Intermediate Shaft Thrust Plate

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11. Check seal ring on rear clutch retainer hub and seal rings on input shaft (Fig 10). Also verify that shaft seal rings are installed in sequence shown.
    Fig 10: Locating Input Shaft Seal Ring

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12. Install rear clutch thrust washer (Fig 11). Use additional petroleum jelly to hold washer in place if necessary.
    Fig 11: Installing Rear Clutch Thrust Washer

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13. Align clutch discs in front clutch and install front clutch on rear clutch (Fig 12). Rotate front clutch retainer back and forth until completely seated on rear clutch retainer.
    Fig 12: Assembling Front And Rear Clutch Units

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14. Coat intermediate shaft thrust washer with petroleum jelly. Then install washer in rear clutch hub (Fig 13). Use enough petroleum jelly to hold washer in place. Be sure grooved side of washer faces rearward (toward output shaft) as shown. Also note that washer only fits one way in clutch hub. Note thickness of this washer. It is a select fit part and is used to control transmission end play.
    Fig 13: Installing Intermediate Shaft Thrust Washer

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15. Align drive teeth on rear clutch discs with small screwdriver (Fig 14). This makes installation on front planetary easier.
    Fig 14: Aligning Rear Clutch Disc Lugs

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16. Raise front end of transmission upward as far as possible and support case with wood blocks. Front/ rear clutch and oil pump assemblies are easier to install if transmission is as close to upright position as possible.
17. Slide front band into case.
18. Install front and rear clutch units as assembly (Fig 15). Align rear clutch with front annulus gear and install assembly in driving shell. Be sure output shaft thrust washer and thrust plate are not displaced during installation.
    Fig 15: Installing Front/Rear Clutch Assemblies

    Courtesy of DAIMLERCHRYSLER CORP.
19. Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear. Also be sure front clutch drive lugs are fully engaged in slots of driving shell after installation.
20. Assemble front band strut.
21. Install front band adjuster, strut and adjusting screw (Fig 16).
    Fig 16: Installing Front Band Linkage

    Courtesy of DAIMLERCHRYSLER CORP.
22. Tighten band adjusting screw until band just grips clutch retainer. Verify that front/rear clutches are still seated before continuing.
23. Check seal rings on reaction shaft support hub. Verify that seal rings are hooked together and that reaction shaft thrust washer is properly positioned (Fig 17). Use petroleum jelly to hold thrust washer in place if necessary.
    Fig 17: Identifying Reaction Shaft Support Seal Rings And Thrust Washer

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24. Lubricate oil pump body seal with petroleum jelly. Lubricate pump shaft seal lip with petroleum jelly.
25. Thread two Pilot Stud Tools C-3288-B into bolt holes in oil pump bore flange (Fig 18).
    Fig 18: Installing Pilot Studs And Oil Pump Gasket

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26. Align and install oil pump gasket (Fig 18).
27. Install oil pump (Fig 19). Align and position pump on pilot studs. Slide pump down studs and work it into front clutch hub and case by hand. Then install 2 or 3 pump bolts to hold pump in place.
28. Remove pilot stud tools and install remaining oil pump bolts. Tighten bolts alternately in diagonal pattern to 20 N.m (15 ft. lbs.).
    Fig 19: Installing Oil Pump

    Courtesy of DAIMLERCHRYSLER CORP.
29. Measure input shaft end play (Fig 20).
    NOTE: If end play is incorrect, transmission is incorrectly assembled, or the intermediate shaft thrust washer is incorrect. The intermediate shaft thrust washer is selective.
    1. Attach Adapter 8266-6 to Handle 8266-8.
    2. Attach dial indicator C-3339 to Handle 8266-8.
    3. Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266-6 to secure it to the input shaft.
    4. Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.
    5. Move input shaft in and out and record reading. End play should be 0.56-2.31 mm (0.022-0.091 in.). Adjust as necessary.
    Fig 20: Measuring Input Shaft End Play

    Courtesy of DAIMLERCHRYSLER CORP.
30. Install accumulator piston and inner and outer springs (Fig 21).
    Fig 21: Installing Accumulator Piston And Inner And Outer Springs

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31. Verify that valve body solenoid harness is secured in 3-4 accumulator housing cover plate.
32. Install valve body as follows:
    1. Align and carefully insert park rod into pawl. Rod will make click noise as it enters pawl. Move rod slightly to check engagement.
    2. Align and seat valve body on case. Be sure manual lever shaft and overdrive connector are fully seated in case. Also be sure valve body wiring is not pinched or kinked.
    3. Install and start all valve body attaching bolts by hand. Then tighten bolts evenly, in a diagonal pattern to 12 N.m (105 in. lbs.) torque. Do not overtighten valve body bolts. This could result in distortion and cross leakage after installation.
    CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into the cavity.
33. Install new filter on valve body. Tighten filter screws to 4 N.m (35 in. lbs.).
34. Adjust front and rear bands.
35. Install new valve body manual shaft seal in case (Fig 22). Lubricate seal lip and manual shaft with petroleum jelly. Start seal over shaft and into case. Seat seal with 15/16 inch, deep well socket.
    Fig 22: Installing Manual Lever Shaft Seal

    Courtesy of DAIMLERCHRYSLER CORP.
36. Thread the transmission range sensor mounting bracket into the transmission case, if necessary. Use Adapter 8581 and an appropriate torque wrench to torque the mounting bracket to 34 N.m (300 in. lbs.) (Fig 23).
    Fig 23: Tightening TRS Mounting Bracket

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37. Install the transmission range sensor (Fig 24) into the mounting bracket with the electrical connector facing the front of the transmission. Install the screws to hold the sensor to the mounting bracket and tighten to 3.4 N.m (30 in.lbs.).
    Fig 24: Installing Transmission Range Sensor

    Courtesy of DAIMLERCHRYSLER CORP.
38. Install magnet in oil pan. Magnet goes on small protrusion at corner of pan.
39. Position new oil pan gasket on case and install oil pan. Tighten pan bolts to 17 N.m (13 ft. lbs.).
40. Install throttle valve and shift selector levers on valve body manual lever shaft.