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Home >> Dodge and Ram >> 2003 >> Durango Base, 5.9 Z, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 95 (Overhaul - 42RLE Automatic Transmission) >> Automatic Transmission - 42RLE >> Disassembly

Automatic Transmission - 42RLE: 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.
NOTE: If the transmission 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 .

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

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.
  1. Remove the torque converter from the transmission input shaft ( Fig 1).
    Fig 1: Removing Torque Converter
    G03489040Courtesy of DAIMLERCHRYSLER CORP.
  2. Measure input shaft end play using Tool 8266. Set up Tool 8266 and a dial indicator as shown in ( Fig 2). 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 2: Measuring Input Shaft End Play Using Tool 8266
    G03489041Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: The four bolts along the bottom of the adapter or extension housing have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.
  3. Remove the bolts ( Fig 3) that hold the adapter or extension housing onto the transmission case.
    Fig 3: Removing Adapter Housing Bolts
    G03489042Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove the adapter ( Fig 4) or extension ( Fig 5) housing from the transmission case. There are two pry slots ( Fig 6) located near the bottom corners of the housing for separating the housing from the transmission case.
    Fig 4: Removing Adapter Housing
    G03489043Courtesy of DAIMLERCHRYSLER CORP.
    Fig 5: Removing Extension Housing
    G03489044Courtesy of DAIMLERCHRYSLER CORP.
  5. Inspect the lube tube grommet ( Fig 6) for damage. If the grommet lip is damaged, it will need to be replaced.
    Fig 6: Locating Lube Tube Grommet
    G03489045Courtesy of DAIMLERCHRYSLER CORP.
  6. On 4X2 transmissions, perform the following, if necessary.
    1. Remove the extension shaft bearing snap ring ( Fig 7) from the extension housing.
      Fig 7: Removing Extension Shaft Bearing Snap Ring
      G03489046Courtesy of DAIMLERCHRYSLER CORP.
    2. Remove the extension shaft and bearing assembly ( Fig 8) from the extension housing.
      Fig 8: Removing Extension Shaft And Bearing Assembly
      G03489047Courtesy of DAIMLERCHRYSLER CORP.
    3. Remove the extension shaft bearing retaining ring ( Fig 9) from the extension shaft.
      Fig 9: Removing Extension Shaft Bearing Retaining Ring
      G03489048Courtesy of DAIMLERCHRYSLER CORP.
    4. Remove the extension shaft bearing ( Fig 10) from the extension shaft.
      Fig 10: Removing Extension Shaft Bearing
      G03489049Courtesy of DAIMLERCHRYSLER CORP.
  7. Using a Slide Hammer C-3752 ( Fig 11), remove the 4X4 stub shaft ( Fig 12) from the transmission output shaft. Inspect the cir-clip on the shaft for damage and replace the clip if necessary.
    Fig 11: Removing 4X4 Stub Shaft Using C-3752
    G03489050Courtesy of DAIMLERCHRYSLER CORP.
    Fig 12: Removing 4X4 Stub Shaft
    G03489051Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the input speed sensor bolt ( Fig 13).
  9. Remove the output speed sensor bolt ( Fig 14).
    NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
    Fig 13: Removing Input Speed Sensor Bolt
    G03489052Courtesy of DAIMLERCHRYSLER CORP.
    Fig 14: Removing Output Speed Sensor Bolt
    G03489053Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove the input and output speed sensors ( Fig 15). Identify the speed sensors for re-installation since they are not interchangeable.
    Fig 15: Removing Output Speed Sensor
    G03489054Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.
  11. Remove the transmission oil pan bolts ( Fig 16)
  12. Remove the transmission oil pan ( Fig 17).
    Fig 16: Removing Transmission Oil Pan Bolts
    G03489055Courtesy of DAIMLERCHRYSLER CORP.
    Fig 17: Removing Transmission Oil Pan
    G03489056Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove the transmission oil filter screws ( Fig 18).
    Fig 18: Removing Oil Filter Screws
    G03489057Courtesy of DAIMLERCHRYSLER CORP.
  14. Remove transmission oil filter ( Fig 19).
    Fig 19: Removing Transmission Filter
    G03489058Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the oil filter o-ring from the valve body ( Fig 20)
    Fig 20: Removing Oil Filter O-Ring
    G03489059Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove valve body-to-case bolts ( Fig 21).
    Fig 21: Removing Valve Body Bolts
    G03489060Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
  17. Remove valve body from transmission ( Fig 22).
    Fig 22: Removing Valve Body From Transmission
    G03489061Courtesy of DAIMLERCHRYSLER CORP.
  18. Remove underdrive and overdrive accumulators ( Fig 23).
    Fig 23: Removing Underdrive And Overdrive Accumulators
    G03489062Courtesy of DAIMLERCHRYSLER CORP.
  19. Remove the low/reverse accumulator snap ring ( Fig 24).
    Fig 24: Removing Low/Reverse Accumulator
    G03489063Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove the low/reverse accumulator plug ( Fig 25).
    Fig 25: Removing Low/Reverse Accumulator Plug
    G03489064Courtesy of DAIMLERCHRYSLER CORP.
  21. Remove low/reverse accumulator piston using suitable pliers ( Fig 26). Remove piston and springs ( Fig 27).
    Fig 26: Removing Low/Reverse Accumulator Piston
    G03489065Courtesy of DAIMLERCHRYSLER CORP.
    Fig 27: Removing Low/Reverse Accumulator
    G03489066Courtesy of DAIMLERCHRYSLER CORP.
  22. Remove and discard the oil pump-to-case bolts ( Fig 28). The oil pump bolts are not to be reused.
    Fig 28: Removing Oil Pump Attaching Bolts
    G03489067Courtesy of DAIMLERCHRYSLER CORP.
  23. Remove oil pump using C-3752 Pullers ( Fig 29).
    24. Fig 29: Installing Oil Pump Pullers
    G03489068Courtesy of DAIMLERCHRYSLER CORP.
  24. Remove oil pump while pushing in on input shaft ( Fig 30).
    25. Fig 30: Removing Oil Pump
    G03489069Courtesy of DAIMLERCHRYSLER CORP.
  25. Remove oil pump gasket ( Fig 31).
    Fig 31: Removing Oil Pump Gasket
    G03489070Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: By-pass valve must be replaced if transmission failure occurs.
  26. Remove the cooler by-pass valve ( Fig 32).
    Fig 32: Removing By-Pass Valve
    G03489071Courtesy of DAIMLERCHRYSLER CORP.
  27. Remove the #1 caged needle bearing ( Fig 33).
    Fig 33: Removing Caged Needle Bearing
    G03489072Courtesy of DAIMLERCHRYSLER CORP.
  28. Remove the input clutch assembly ( Fig 34).
    Fig 34: Removing Input Clutch Assembly
    G03489073Courtesy of DAIMLERCHRYSLER CORP.
  29. Remove the #4 thrust plate ( Fig 35).
    Fig 35: Removing Thrust Plate
    G03489074Courtesy of DAIMLERCHRYSLER CORP.
  30. Remove the front sun gear assembly and #4 thrust washer (if still in place) ( Fig 36).
    Fig 36: Removing Front Sun Gear Assembly
    G03489075Courtesy of DAIMLERCHRYSLER CORP.
  31. Remove the front carrier/rear annulus and #6 needle bearing ( Fig 37).
    Fig 37: Removing Front Carrier/Rear Annulus
    G03489076Courtesy of DAIMLERCHRYSLER CORP.
  32. Remove the rear sun gear and #7 needle bearing ( Fig 38) ( Fig 39).
    Fig 38: Removing Rear Sun Gear
    G03489077Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: The number seven needle bearing 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 ( Fig 39). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
    Fig 39: Removing Bearing
    G03489078Courtesy of DAIMLERCHRYSLER CORP.
    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.
  33. Install and load Tool 5058A to remove the 2/4 clutch retainer snap ring ( Fig 40).
    Fig 40: Removing Clutch Retainer Snap Ring
    G03489079Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
  34. Remove the 2/4 clutch retainer ( Fig 41) ( Fig 42).
    Fig 41: Removing Clutch Retainer
    G03489080Courtesy of DAIMLERCHRYSLER CORP.
    Fig 42: Removing Clutch Retainer
    G03489081Courtesy of DAIMLERCHRYSLER CORP.
  35. Remove the 2/4 clutch return spring ( Fig 43).
    Fig 43: Removing Clutch Return Spring
    G03489082Courtesy of DAIMLERCHRYSLER CORP.
  36. Remove the 2/4 clutch pack ( Fig 44).
    Fig 44: Removing Clutch Pack
    G03489083Courtesy of DAIMLERCHRYSLER CORP.
  37. Remove the tapered snap ring ( Fig 45).
    Fig 45: Removing Tapered Snap Ring
    G03489084Courtesy of DAIMLERCHRYSLER CORP.
  38. Remove the low/reverse reaction plate ( Fig 46).
    Fig 46: Removing Low/Reverse Reaction Plate
    G03489085Courtesy of DAIMLERCHRYSLER CORP.
  39. Remove one (1) low/reverse clutch disc to facilitate snap ring removal ( Fig 47).
    Fig 47: Removing Disc
    G03489086Courtesy of DAIMLERCHRYSLER CORP.
  40. Remove the low/reverse reaction plate snap ring ( Fig 48).
    Fig 48: Removing Low/Reverse Reaction Plate Snap Ring
    G03489087Courtesy of DAIMLERCHRYSLER CORP.
  41. Remove the low/reverse clutch pack ( Fig 49).
    Fig 49: Removing Low/Reverse Clutch Pack
    G03489088Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Failure to grind and open stakes of the output shaft nut will result in thread damage to the shaft during nut removal.
    WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.
  42. Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in ( Fig 50) ( Fig 51). Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
    Fig 50: Grinding Stakes
    G03489089Courtesy of DAIMLERCHRYSLER CORP.
    Fig 51: Identifying Stake Grinding Pattern
    G03489090Courtesy of DAIMLERCHRYSLER CORP.
  43. Using a small chisel, carefully open the stakes on nut ( Fig 52).
    Fig 52: Opening Nut Stakes
    G03489091Courtesy of DAIMLERCHRYSLER CORP.
  44. Use special tool 6497 and 6498A to remove the transfer shaft nut or the output shaft nut ( Fig 53).
    Fig 53: Removing Output Shaft Nut
    G03489092Courtesy of DAIMLERCHRYSLER CORP.
  45. Remove the output shaft from case using a shop press ( Fig 54).
    Fig 54: Removing Output Shaft From Case
    G03489093Courtesy of DAIMLERCHRYSLER CORP.

    Use special tool 6596 with a shop press to remove the front output shaft bearing cup ( Fig 55).

    Fig 55: Removing Front Bearing Cup
    G03489094Courtesy of DAIMLERCHRYSLER CORP.
  46. Use special tool 6597 and handle C-4171 and C-4171-2 to press the rear output shaft bearing cup rearward ( Fig 56).
    Fig 56: Removing Rear Bearing Cup
    G03489095Courtesy of DAIMLERCHRYSLER CORP.
  47. Remove the rear carrier front bearing cone ( Fig 57).
    Fig 57: Removing Rear Carrier Front Bearing Cone
    G03489096Courtesy of DAIMLERCHRYSLER CORP.
  48. Install and load compressor ( Fig 58) as shown in ( Fig 59).
    Fig 58: Installing Low/Reverse Spring Compressor Tool
    G03489097Courtesy of DAIMLERCHRYSLER CORP.
    Fig 59: Installing Compressor Tool
    G03489098Courtesy of DAIMLERCHRYSLER CORP.
  49. Remove the low/reverse belleville spring snap ring ( Fig 60).
    Fig 60: Removing Snap Ring
    G03489099Courtesy of DAIMLERCHRYSLER CORP.
  50. Remove the low/reverse piston belleville spring ( Fig 61).
    Fig 61: Removing Low/Reverse Piston Belleville Spring
    G03489100Courtesy of DAIMLERCHRYSLER CORP.
  51. Remove the park sprag pivot retaining screw.
  52. Drive out the anchor shaft using suitable punch ( Fig 62)
    Fig 62: Removing Anchor Shaft
    G03489101Courtesy of DAIMLERCHRYSLER CORP.
  53. Remove the guide bracket pivot shaft ( Fig 63). Inspect all components for wear and replace if necessary.
    Fig 63: Removing Guide Bracket Pivot Shaft
    G03489102Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
  54. Remove the low/reverse clutch piston ( Fig 64).
    Fig 64: Removing Law/Reverse Clutch Piston
    G03489103Courtesy of DAIMLERCHRYSLER CORP.
  55. Remove the low/reverse piston retainer screws.
  56. Remove low/reverse piston retainer ( Fig 65).
    Fig 65: Removing Piston Retainer
    G03489104Courtesy of DAIMLERCHRYSLER CORP.
  57. Remove the low/reverse piston retainer gasket ( Fig 66).
    Fig 66: Removing Piston Retainer Gasket
    G03489105Courtesy of DAIMLERCHRYSLER CORP.
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