LEMON Manuals: Even more car manuals for everyone
Home >> Dodge and Ram >> 2003 >> Durango Base, 5.9 Z, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 59 (Overhaul - 42RE Automatic Transmission) >> Overdrive Unit >> Assembly >> GEARTRAIN And Direct Clutch

GEARTRAIN And Direct Clutch

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. Soak direct clutch and overdrive clutch discs in Mopar® ATF +4, Automatic Transmission fluid. Allow discs to soak for 10-20 minutes.
  2. Install new pilot bushing and clutch hub bushing in output shaft if necessary (Fig 1). Lubricate bushings with petroleum jelly, or transmission fluid.
    Fig 1: Identifying Output Shaft Pilot Bushing
    G02657699Courtesy of DAIMLERCHRYSLER CORP.
  3. Install annulus gear on output shaft, if removed. Then install annulus gear retaining snap-ring (Fig 2).
    Fig 2: Installing Annulus Gear
    G02657700Courtesy of DAIMLERCHRYSLER CORP.
  4. Align and install clutch drum on annulus gear (Fig 3). Be sure drum is engaged in annulus gear lugs.
    Fig 3: Installing Clutch Drum And Outer Retaining Ring
    G02657701Courtesy of DAIMLERCHRYSLER CORP.
  5. Install clutch drum outer retaining ring (Fig 3).
  6. Slide clutch drum forward and install inner retaining ring (Fig 4).
    Fig 4: Installing Clutch Drum Inner Retaining Ring
    G02657702Courtesy of DAIMLERCHRYSLER CORP.
  7. Install rear bearing and snap-ring on output shaft (Fig 5). Be sure locating ring groove in bearing is toward rear.
    Fig 5: Installing Rear Bearing And Snap-Ring
    G02657703Courtesy of DAIMLERCHRYSLER CORP.
  8. Install overrunning clutch on hub (Fig 6). Note that clutch only fits one-way. Shoulder on clutch should seat in small recess at edge of hub.
    Fig 6: Assembling Overrunning Clutch And Hub
    G02657704Courtesy of DAIMLERCHRYSLER CORP.
  9. Install thrust bearing on overrunning clutch hub. Use generous amount of petroleum jelly to hold bearing in place for installation. Bearing fits one-way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does not seat squarely.
  10. Install overrunning clutch in output shaft (Fig 7). Insert snap-ring pliers in hub splines. Expand pliers to grip hub. Then install assembly with counterclockwise, twisting motion.
    Fig 7: Installing Overrunning Clutch
    G02657705Courtesy of DAIMLERCHRYSLER CORP.
  11. Install planetary gear in annulus gear (Fig 8). Be sure planetary pinions are fully seated in annulus gear before proceeding.
    Fig 8: Installing Planetary Gear
    G02657706Courtesy of DAIMLERCHRYSLER CORP.
  12. Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly. This will help hold bearing in place during installation.
  13. Install planetary thrust bearing on sun gear (Fig 9). Slide bearing onto gear and seat it against spring plate as shown. Bearing fits one-way only. If it does not seat squarely against spring plate, remove and reposition bearing.
    Fig 9: Installing Planetary Thrust Bearing
    G02657707Courtesy of DAIMLERCHRYSLER CORP.
  14. Install assembled sun gear, spring plate and thrust bearing (Fig 10). Be sure sun gear and thrust bearing are fully seated before proceeding.
    Fig 10: Installing Sun Gear
    G02657708Courtesy of DAIMLERCHRYSLER CORP.
  15. Mount assembled output shaft, annulus gear, and clutch drum in shop press. Direct clutch spring, hub and clutch pack are easier to install with assembly mounted in press.
  16. Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227-2 (Fig 11). Insert tool through sun gear and into splines of both hubs. Be sure alignment tool is fully seated before proceeding.
    Fig 11: Aligning Splines In Hubs Of Planetary Gear And Overrunning Clutch
    G02657709Courtesy of DAIMLERCHRYSLER CORP.
  17. Install direct clutch spring (Fig 12). Be sure spring is properly seated on spring plate.
    Fig 12: Installing Direct Clutch Spring
    G02657710Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: The 42RE transmission has 6 direct clutch discs and 5 clutch plates.
  18. Assemble and install direct clutch pack on hub as follows:
    1. Assemble clutch pack components (Fig 13).
      Fig 13: Exploded View Of 42RE Direct Clutch Pack Components
      G02657711Courtesy of DAIMLERCHRYSLER CORP.
    2. Install direct clutch reaction plate on clutch hub first. Note that one side of reaction plate is counterbored. Be sure this side faces rearward. Splines at rear of hub are raised slightly. Counterbore in plate fits over raised splines. Plate should be flush with this end of hub (Fig 14).
      Fig 14: Correcting Position Of Direct Clutch Reaction Plate
      G02657712Courtesy of DAIMLERCHRYSLER CORP.
    3. Install first clutch disc followed by a steel plate until all discs and plates have been installed.
    4. Install pressure plate. This is last clutch pack item to be installed. Be sure plate is installed with shoulder side facing upward (Fig 15).
      Fig 15: Correcting Position Of Direct Clutch Pressure Plate
      G02657713Courtesy of DAIMLERCHRYSLER CORP.
  19. Install clutch hub and clutch pack on direct clutch spring (Fig 16). Be sure hub is started on sun gear splines before proceeding.
    Fig 16: Installing Clutch Hub And Clutch Pack On Direct Clutch Spring
    G02657714Courtesy of DAIMLERCHRYSLER CORP.
    WARNING: THE NEXT STEP IN GEARTRAIN ASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING. IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE COMPRESSOR TOOL C-6227-1 AND A HYDRAULIC-TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6 INCHES. THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED. RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY.
  20. Position Compressor Tool 6227-1 on clutch hub.
  21. Compress clutch hub and spring just enough to place tension on hub and hold it in place.
  22. Slowly compress clutch hub and spring. Compress spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring.
  23. Realign clutch pack on hub and seat clutch discs and plates in clutch drum.
  24. Install direct clutch pack snap-ring (Fig 17). Be very sure snap-ring is fully seated in clutch drum ring groove.
    Fig 17: Installing Direct Clutch Pack Snap-Ring
    G02657715Courtesy of DAIMLERCHRYSLER CORP.
  25. Install clutch hub retaining ring (Fig 18). Be very sure retaining ring is fully seated in sun gear ring groove.
    Fig 18: Installing Clutch Hub Retaining Ring
    G02657716Courtesy of DAIMLERCHRYSLER CORP.
  26. Slowly release press ram, remove compressor tools and remove geartrain assembly.
scientia non olet · About LEMON Manuals