Automatic Transmission - 42RLE: Assembly

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.

NOTE: If the transmission assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIII® Scan Tool. Refer to STANDARD PROCEDURE--DRIVE LEARN .

Install the output bearing cups using Special Tool - 5050A ( Fig 1).

Fig 1: Installing Special Tool - 5050A
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Install-low/reverse piston retainer gasket. ( Fig 2).

Fig 2: Installing Piston Retainer Gasket
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Install low/reverse piston retainer ( Fig 3).

Fig 3: Installing Piston Retainer
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Install low/reverse piston retainer-to-case screws ( Fig 4) and torque to 5 N.m (45 in. lbs.).

Fig 4: Installing Retainer Attaching Screws
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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 ( Fig 5).

Fig 5: Installing Low/Reverse Clutch Piston
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Assemble guide bracket assembly as shown in ( Fig 6). if necessary.

Fig 6: Installing Guide Bracket Assembly
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Install guide bracket pivot shaft ( Fig 7).

Fig 7: Installing Guide Bracket Pivot Shaft
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CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case.
Install park sprag pivot retaining screw and torque to 4.5 N.m (40 in. lbs.).
Install low/reverse piston belleville spring into position ( Fig 8).

Fig 8: Installing Low/Reverse Piston Return Spring
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Install and load low/reverse spring compressor tool as shown in ( Fig 9) ( Fig 10) to facilitate snap ring installation.

Fig 9: Installing Low/Reverse Spring Compressor Tool
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Fig 10: Installing Special Tool
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Install snap ring and remove compressor tool ( Fig 11).

Fig 11: Installing Snap Ring
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Install rear carrier front bearing cone ( Fig 12).

Fig 12: Installing Rear Carrier Front Bearing Cone
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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
1. PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and special tool 6618A ( Fig 13).
  
  Fig 13: Installing Bearing
  Courtesy of DAIMLERCHRYSLER CORP.
2. Install special tool 6618A ( Fig 14). Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
  
  Fig 14: Installing Special Tool
  Courtesy of DAIMLERCHRYSLER CORP.
3. 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 tool 6618A. Ensure your press table has clearance for the output shaft.
4. Install shim on output shaft ( Fig 15). 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.
  
  Fig 15: Installing Shim
  Courtesy of DAIMLERCHRYSLER CORP.
5. Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) and C-4171 and C4171-2 (Handle) to press shaft into rear bearing ( Fig 16).
  
  Fig 16: Pressing Shaft Into Case
  Courtesy of DAIMLERCHRYSLER CORP.
6. Do not re-use old output shaft nut because the removed stake weakens the nut flange. Using special tools 6497 and 6498-A, install new output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.).
7. Check the turning torque of the output shaft ( Fig 17). 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.
  
  Fig 17: Checking Turning Torque
  Courtesy of DAIMLERCHRYSLER CORP.
8. The new nut must be staked after the correct turning torque is obtained ( Fig 18) ( Fig 19). Use special tool 6639 to stake output shaft nut.
  CAUTION: Failure to stake nut could allow the nut to back-off during use.
  
  Fig 18: Staking Output Shaft Nut
  Courtesy of DAIMLERCHRYSLER CORP.
  
  Fig 19: Staking Nut
  Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse clutch pack ( Fig 20). Leave uppermost disc out to facilitate snap ring installation.

Fig 20: Installing Low/Reverse Clutch Pack
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Install low/reverse reaction plate snap ring ( Fig 21).

Fig 21: Installing Low/Reverse Reaction Plate Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Install one low/reverse clutch disc ( Fig 22).

Fig 22: Installing Disc
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Install low/reverse reaction plate with flat side up ( Fig 23).

Fig 23: Installing Low/Reverse Reaction Plate
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Install a new tapered snap ring (tapered side out) ( Fig 24). Make sure that the snap ring ends are oriented as shown ( Fig 25)

Fig 24: Installing Snap Ring
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Fig 25: Viewing Tapered Snap Ring
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Measure low/reverse clutch pack. Set up dial indicator as shown in ( Fig 26). 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).

Fig 26: Checking Low/Reverse Clutch Clearance
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Select the proper low/reverse reaction plate to achieve specifications.
Install 2/4 clutch pack ( Fig 27).

Fig 27: Installing Clutch Pack
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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 ( Fig 28) ( Fig 29).

Fig 28: Installing Clutch Return Spring
Courtesy of DAIMLERCHRYSLER CORP.

Fig 29: Identifying Proper Orientation Of Clutch
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Install 2/4 clutch retainer ( Fig 30).

Fig 30: Installing Clutch Retainer
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NOTE: Verify that Tool 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
Set up Tool 5058 as shown in ( Fig 31). Compress 2/4 clutch just enough to facilitate snap ring installation.

Fig 31: Removing Clutch Retainer Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Measure 2/4 clutch clearance: Set up dial indicator as shown in ( Fig 32). 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.

Fig 32: Checking Clutch Clearance
Courtesy of DAIMLERCHRYSLER CORP.
Install the #7 needle bearing to the rear sun gear ( Fig 33). The number 7 needle bearing has three antireversal 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.

Fig 33: Installing Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install rear sun gear and #7 needle bearing ( Fig 34).

Fig 34: Installing Rear Sun Gear
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Install front carrier/rear annulus assembly and #6 needle bearing ( Fig 35).

Fig 35: Installing Front Carrier/Rear Annulus
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Install front sun gear assembly and #4 thrust washer ( Fig 36).

Fig 36: Installing Front Sun Gear Assembly
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Determine proper #4 thrust plate thickness.
1. Select the thinnest #4 thrust plate thickness.
2. Install #4 thrust plate ( Fig 37) using petrolatum to hold into position.
3. 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.
  
  Fig 37: Installing Thrust Plate
  Courtesy of DAIMLERCHRYSLER CORP.
4. Remove the oil pump o-ring ( Fig 38) 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.
  
  Fig 38: Removing Oil Pump O-Ring
  Courtesy of DAIMLERCHRYSLER CORP.
5. Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate.
6. Set up and measure endplay using End Play Set 8266 and Dial Indicator Set C3339 as shown in ( Fig 39).
  
  Fig 39: Measuring Input Shaft End Play Using Tool 8266
  Courtesy of DAIMLERCHRYSLER CORP.
7. 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.
8. Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
Install input clutch assembly with proper thrust plate ( Fig 40).

Fig 40: Installing Input Clutch Assembly
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Install #1 caged needle bearing ( Fig 41).

Fig 41: Installing Caged Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Replace cooler by-pass valve if transmission failure has occurred ( Fig 42).
CAUTION: By-pass valve MUST be replaced if transmission failure occurs.

Fig 42: Installing By-Pass Valve
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.
Install oil pump gasket ( Fig 43).

Fig 43: Installing Oil Pump Gasket
Courtesy of DAIMLERCHRYSLER CORP.
Install oil pump and torque oil pump-to-case bolts to 30 N.m (265 in. lbs.) ( Fig 44). Do not reuse original oil pump bolts.

Fig 44: Installing Oil Pump And Torque Oil Pump-To-Case Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse accumulator as shown in ( Fig 45).

Fig 45: Installing Low/Reverse Accumulator Piston
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse accumulator plug ( Fig 46).

Fig 46: Installing Low/Reverse Accumulator Plug
Courtesy of DAIMLERCHRYSLER CORP.
Install low/reverse accumulator snap ring ( Fig 47).

Fig 47: Installing Low/Reverse Accumulator Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Install underdrive and overdrive accumulators and springs ( Fig 48).

Fig 48: Installing Underdrive And Overdrive Accumulators
Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Install valve body into place as shown in ( Fig 49).

Fig 49: Installing Valve Body Onto Transmission
Courtesy of DAIMLERCHRYSLER CORP.
Install seven (7) valve body-to-case bolts ( Fig 50) and torque to 12 N.m (105 in. lbs.).

Fig 50: Installing Valve Body Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Install transmission oil filter ( Fig 51). Tighten the bolts to 5 N.m (45 in. lbs.).

Fig 51: Installing Transmission Oil Filter
Courtesy of DAIMLERCHRYSLER CORP.

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 ( Fig 52), it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock & Seal Adhesive.

Fig 52: Locating Pan Fastener Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Install transmission oil pan ( Fig 53) with a bead of Mopar® ATF RTV. Torque oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.).
NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock & Seal Adhesive.
Install both speed sensors into transmission case ( Fig 54). Torque the speed sensor bolts to 9 N.m (80 in. lbs.)

Fig 53: Installing Transmission Oil Pan
Courtesy of DAIMLERCHRYSLER CORP.

Fig 54: Installing Input And Output Speed Sensors And Transmission Range Sensor
Courtesy of DAIMLERCHRYSLER CORP.
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 to transmission bell housing with its plunger seated against end of input shaft ( Fig 55). 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.

Fig 55: Measuring Input Shaft End Play Using Tool 8266
Courtesy of DAIMLERCHRYSLER CORP.
On 4X2 transmissions, perform the following, if necessary.
1. Install the extension shaft bearing ( Fig 56) onto the extension shaft.
2. Install the extension shaft bearing retaining ring ( Fig 57) onto the extension shaft.
  
  Fig 56: Installing Extension Shaft Bearing
  Courtesy of DAIMLERCHRYSLER CORP.
  
  Fig 57: Installing Extension Shaft Bearing Retaining Ring
  Courtesy of DAIMLERCHRYSLER CORP.
3. Install the extension shaft and bearing assembly ( Fig 58) into the extension housing.
  
  Fig 58: Installing Extension Shaft And Bearing Assembly
  Courtesy of DAIMLERCHRYSLER CORP.
4. Install the extension shaft bearing snap ring ( Fig 59) into the extension housing.
  
  Fig 59: Installing Extension Shaft Bearing Snap Ring
  Courtesy of DAIMLERCHRYSLER CORP.
5. Verify that the extension shaft snap ring ( Fig 60) is fully engaged in the snap ring groove.
  
  Fig 60: Installing Extension Shaft Bearing Snap Ring
  Courtesy of DAIMLERCHRYSLER CORP.
Inspect the lube tube grommet ( Fig 61) for damage. If the grommet lip is damaged, it will need to be replaced.
Install the 4X4 stub shaft onto the transmission output shaft.

Fig 61: Locating Lube Tube Grommet
Courtesy of DAIMLERCHRYSLER CORP.
Place a bead of Mopar® ATF RTV on the rear surface of the transmission case for the adapter/extension housing.
Install the adapter ( Fig 62) or extension ( Fig 63) housing onto the transmission case.

Fig 62: Installing Adapter Housing
Courtesy of DAIMLERCHRYSLER CORP.

Fig 63: Installing Extension Housing
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NOTE: Before installing the lowermost four adapter/extension housing bolts ( Fig 64), it will be necessary to replenish the sealing patch on the bolts using Mopar® Lock & Seal Adhesive.

Fig 64: Tightening Bolts
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Install the bolts ( Fig 65) 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.).

Fig 65: Installing Adapter Housing Bolts
Courtesy of DAIMLERCHRYSLER CORP.