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Automatic Transmission-42RE: Disassembly

WARNING: This page is about a different car, the 2004 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean transmission exterior with steam gun or with solvent. Wear eye protection during cleaning operations.
  2. Place transmission in a vertical position.
  3. Measure input shaft end play as follows (Fig 1).
    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 the input shaft in and out. Record the maximum travel for assembly reference.
    Fig 1: Measuring Input Shaft End Play
    G02657512Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove shift and throttle levers from valve body manual lever shaft.
  5. Place transmission in horizontal position.
  6. Remove transmission oil pan and gasket.
  7. Remove filter from valve body (Fig 2). Keep filter screws separate from other valve body screws. Filter screws are longer and should be kept with filter.
    Fig 2: Removing Filter From Valve Body
    G02657513Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the transmission range sensor.
  9. Remove hex head bolts attaching valve body to transmission case (Fig 3). A total of 10 bolts are used. Note different bolt lengths for assembly reference.
    Fig 3: Locating Valve Body Bolt
    G02657514Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove valve body assembly. Push valve body harness connector out of case. Then work park rod and valve body out of case (Fig 4).
    Fig 4: Removing Valve Body Assembly
    G02657515Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove accumulator piston and inner and outer springs (Fig 5).
    Fig 5: Removing Accumulator Piston And Inner And Outer Springs
    G02657516Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove pump oil seal with suitable pry tool or slide-hammer mounted screw.
  13. Loosen front band adjusting screw locknut 4-5 turns. Then tighten band adjusting screw until band is tight around front clutch retainer. This prevents front/rear clutches from coming out with pump and possibly damaging clutch or pump components.
  14. Remove oil pump bolts.
  15. Thread bolts of Slide Hammer Tools C-3752 into threaded holes in pump body flange (Fig 6).
    Fig 6: Removing Oil Pump And Reaction Shaft Support Assembly
    G02657517Courtesy of DAIMLERCHRYSLER CORP.
  16. Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case (Fig 6).
  17. Loosen front band adjusting screw until band is completely loose.
  18. Squeeze front band together and remove band strut (Fig 7).
    Fig 7: Removing Front Band Strut
    G02657518Courtesy of DAIMLERCHRYSLER CORP.
  19. Remove front band lever (Fig 8).
    Fig 8: Removing Front Band Lever
    G02657519Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove front band lever shaft plug, if necessary, from converter housing.
  21. Remove front band lever shaft.
  22. Remove front and rear clutch units as assembly. Grasp input shaft, hold clutch units together and remove them from case (Fig 9).
    Fig 9: Removing Front/Rear Clutch Assemblies
    G02657520Courtesy of DAIMLERCHRYSLER CORP.
  23. Lift front clutch off rear clutch (Fig 10). Set clutch units aside for overhaul.
    Fig 10: Separating Front/Rear Clutch Assemblies
    G02657521Courtesy of DAIMLERCHRYSLER CORP.
  24. Remove intermediate shaft thrust washer from front end of shaft or from rear clutch hub (Fig 11).
    Fig 11: Removing Intermediate Shaft Thrust Washer
    G02657522Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove output shaft thrust plate from intermediate shaft hub (Fig 12).
    Fig 12: Removing Intermediate Shaft Thrust Plate
    G02657523Courtesy of DAIMLERCHRYSLER CORP.
  26. Slide front band off driving shell (Fig 13) and remove band from case.
    Fig 13: Removing Front Band
    G02657524Courtesy of DAIMLERCHRYSLER CORP.
  27. Remove planetary geartrain as assembly (Fig 14). Support geartrain with both hands during removal. Do not allow machined surfaces on intermediate shaft or overdrive piston retainer to become nicked or scratched.
    Fig 14: Removing Planetary Geartrain And Intermediate Shaft Assembly
    G02657525Courtesy of DAIMLERCHRYSLER CORP.
  28. If overdrive unit is not to be serviced, install Alignment Shaft 6227-2 into the overdrive unit to prevent misalignment of the overdrive clutches during service of main transmission components.
  29. Loosen rear band adjusting screw 4-5 turns.
  30. Remove low-reverse drum snap-ring (Fig 15).
    Fig 15: Removing Low-Reverse Drum Snap-Ring
    G02657526Courtesy of DAIMLERCHRYSLER CORP.
  31. Remove low-reverse drum and reverse band.
  32. Remove overrunning clutch roller and spring assembly as a unit (Fig 16).
    Fig 16: Removing Overrunning Clutch Roller And Spring Assembly
    G02657527Courtesy of DAIMLERCHRYSLER CORP.
  33. Compress front servo rod guide about 1/8 inch with Valve Spring Compressor C-3422-B (Fig 17).
    Fig 17: Compressing Front Servo Rod Guide
    G02657528Courtesy of DAIMLERCHRYSLER CORP.
  34. Remove front servo rod guide snap-ring. Exercise caution when removing snap-ring. Servo bore can be scratched or nicked if care is not exercised.
  35. Remove compressor tools and remove front servo rod guide, spring and servo piston.
  36. Compress rear servo spring retainer about 1/16 inch with Valve Spring Compressor C-3422-B (Fig 18).
    Fig 18: Compressing Rear Servo Spring
    G02657529Courtesy of DAIMLERCHRYSLER CORP.
  37. Remove rear servo spring retainer snap-ring. Then remove compressor tools and remove rear servo spring and piston.
  38. Inspect transmission components.
    NOTE: To Service the overrunning clutch cam or overdrive piston retainer, refer to OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER .
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