Section 511 (Diagnosis & Overhaul - 42RLE Automatic Transmission): Assembly

WARNING: This page is about a different car, the 2005 Jeep Liberty. 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 scan tool (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) .

Fig 1: Bearing Cup Installation Special Tool - 5050A

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

Fig 2: Removing/Installing Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Install low/reverse piston retainer gasket (2). See Fig 2.

Fig 3: Removing/Installing Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET

Install low/reverse piston retainer (1). See Fig 3.

Fig 4: Install Retainer Attaching Screws

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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - SCREWDRIVER

3 - TORX-LOC SCREWS

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

Fig 5: Removing/Installing Low/Reverse Clutch Piston

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1 - LOW/REVERSE CLUTCH PISTON

2 - D-RING SEAL

3 - D-RING SEAL

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 (1). See Fig 5.

Fig 6: Guide Bracket

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1 - GUIDE BRACKET

2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)

3 - PAWL

Assemble guide bracket (1) assembly as shown in Fig 6, if necessary.

Fig 7: Removing/Installing Guide Bracket Pivot Shaft
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case.
Install guide bracket pivot pin (1). See Fig 7.
Install park sprag pivot retaining screw and torque to 4.5 N.m (40 in. lbs.).

Fig 8: Removing/Installing Low/Reverse Piston Belleville Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

Install low/reverse piston belleville spring (1) into position. See Fig 8

Fig 9: Compressor Tool In Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - TOOL 5058A-3

4 - TOOL 5059A

5 - SPECIAL TOOL 6057

Install and load low/reverse spring compressor tool (3, 4, 5) as shown in Fig 9 to facilitate snap ring (2) installation.

Fig 10: Install Snap Ring

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1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN)

2 - SNAP RING PLIERS

3 - TOOL 6057

Install snap ring (1) and remove compressor tool. See Fig 10

Fig 11: Install Rear Carrier Front Bearing Cone

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1 - ARBOR PRESS

2 - SPECIAL TOOL C-4171

3 - SPECIAL TOOL 6052

4 - REAR CARRIER

Install rear carrier (4) front bearing cone. See Fig 11

Fig 12: Bearing Installation
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1 - SPECIAL TOOL 6618-A

2 - REAR OUTPUT SHAFT BEARING

Check output bearing preload. Output bearing preload must be checked and/or adjusted if any of the following items have been replaced:
1. Output shaft (rear carrier assembly)
2. Output shaft bearings
3. Transmission case
PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and special tool 6618A (1). See Fig 12.

Fig 13: Special Tool Installed
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1 - SPECIAL TOOL 6618-A
Install special tool 6618A (1). See Fig 13. Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
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.

Fig 14: Shim Installation
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1 - SHIM

2 - OUTPUT SHAFT
Install shim (1) on output shaft (2). See Fig 14. 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: Press Shaft Into Case
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1 - SPECIAL TOOL C-4171 AND C-4171-2

2 - SPECIAL TOOL MD-998911

Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) (2) and C- 4171 and C4171-2 (Handle) (1) to press shaft into rear bearing. See Fig 15.

Fig 16: Checking Turning Torque

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1 - TORQUE WRENCH

2 - SPECIAL TOOL 6498-A

3 - OUTPUT SHAFT NUT

CAUTION: 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.).

Check the turning torque (1) of the output shaft. See Fig 16. 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: Staking Output Shaft Nut - Typical

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1 - ARBOR PRESS

2 - STAKING TOOL - 6639

3 - NEW NUT

CAUTION: Failure to stake nut could allow the nut to back-off during use.

The new nut (3) must be staked after the correct turning torque is obtained. See Fig 17. Use special tool 6639 (2) to stake output shaft nut.

Fig 18: Properly Staked Nut
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1 - BOTTOMED IN SLOT

2 - CORRECTLY STAKED NUT
Verify that the nut has been properly staked to the output shaft. See Fig 18.

Fig 19: Removing/Installing Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Install low/reverse clutch pack (1, 2). See Fig 19. Leave uppermost disc out to facilitate snap ring installation.

Fig 20: Removing/Installing Low/Reverse Reaction Plate Snap Ring

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1 - SCREWDRIVER

2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

3 - DO NOT SCRATCH CLUTCH PLATE

Install low/reverse reaction plate snap ring (2). See Fig 20.

Fig 21: Removing/Installing One Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH
Install one low/reverse clutch disc (1). See Fig 21.

Fig 22: Removing/Installing Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Install low/reverse reaction plate (1) with flat side up. See Fig 22

Fig 23: Snap Ring Installed
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1 - SCREWDRIVER

2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Install a new tapered snap ring (2) (tapered side out). See Fig 23.

Fig 24: Tapered Snap Ring Instructions
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Make sure that the snap ring ends are oriented as shown. See Fig 24.

Fig 25: Check Low/Reverse Clutch Clearance

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1 - DIAL INDICATOR

2 - DIAL INDICATOR TIP TOOL 6268

3 - HOOK TOOL

Measure low/reverse clutch pack. Set up dial indicator (1) as shown. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. See Fig 25.Low/Reverse clutch pack clearance is 0.84 to 1.60 mm (0.033 to 0.063 inch).
Select the proper low/reverse reaction plate to achieve specifications.

Fig 26: Removing/Installing 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)
Install 2/4 clutch pack (1, 2). See Fig 26.

Fig 27: Removing/Installing 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING

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 (1). See Fig 27.

Fig 28: Proper Orientation of 2/4 Clutch Retainer and Spring

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1 - NOTE POSITION

2 - RETURN SPRING

3 - 2/4 CLUTCH RETAINER

Verify the proper orientation of the return spring (2) to the 2/4 retainer (3). See Fig 28.

Fig 29: Install 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

Install 2/4 clutch retainer (1). See Fig 29.

Fig 30: Remove 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE: Verify that Tool 5058A (1) is centered properly over the 2/4 clutch retainer (4) 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 (1) as shown. Compress 2/4 clutch just enough to facilitate snap ring installation. See Fig 30.

Fig 31: Check 2/4 Clutch Clearance

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1 - DIAL INDICATOR

2 - HOOK TOOL

3 - DIAL INDICATOR TIP TOOL 6268

Measure 2/4 clutch clearance: Set up dial indicator (1) as shown. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. See Fig 31.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: Locating Rear Sun Gear & No. 7 Needle Bearing
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1 - #7 BEARING

2 - REAR SUN GEAR
Install the #7 needle bearing (1) to the rear sun gear (2). See Fig 32. 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: Removing/Installing Rear Sun Gear
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Install rear sun gear (2) and #7 needle bearing (1). See Fig 33.

Fig 34: Removing/Installing Front Carrier/Rear Annulus

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1 - #6 NEEDLE BEARING

2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

Install front carrier/rear annulus assembly (2) and #6 needle bearing (1). See Fig 34.

Fig 35: Removing/Installing Front Sun Gear Assembly
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Install front sun gear assembly (1) and #4 thrust washer (2). See Fig 35.

Fig 36: Removing/Installing #4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate.
Install #4 thrust plate (2) using petrolatum to hold into position. See Fig 36.
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: Remove Oil Pump O-Ring
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1 - OIL PUMP ASSEMBLY

2 - O-RING

Remove the oil pump o-ring (2) and install oil pump and gasket to transmission. See Fig 37.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: Measuring Input Shaft End Play Using End Play Set 8266

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate.
Set up and measure endplay using End Play Set 8266 (1, 2) and Dial Indicator Set C3339 (3) as shown. See Fig 38.
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.

Fig 39: Removing/Installing Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY
Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
Install input clutch assembly (1) with proper thrust plate. See Fig 39.

Fig 40: Removing/Installing No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Install #1 caged needle bearing (1). See Fig 40.

Fig 41: Removing/Installing By-Pass Valve
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1 - BYPASS VALVE

CAUTION: By-pass valve MUST be replaced if transmission failure occurs.
Replace cooler by-pass valve (1) if transmission failure has occurred. See Fig 41.
NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.

Fig 42: Removing/Installing Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Install oil pump gasket (2). See Fig 42.

Fig 43: Removing/Installing Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP
Install oil pump (2) and torque oil pump-to-case bolts (1) to 30 N.m (265 in. lbs.). Do not reuse original oil pump bolts. See Fig 43.

Fig 44: Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON
Install low/reverse accumulator (1) as shown. See Fig 44.

Fig 45: Removing/Installing Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Install low/reverse accumulator plug (2). See Fig 45.

Fig 46: Removing/Installing Low/Reverse Accumulator Snap Ring
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Install low/reverse accumulator snap ring (1). See Fig 46.

Fig 47: Underdrive and Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Install underdrive (2) and overdrive (1) accumulators and springs. See Fig 47.

Fig 48: Removing/Installing Valve Body
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1 - VALVE BODY

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Install valve body (1) into place as shown. See Fig 48.

Fig 49: Removing/Installing Valve Body Bolts
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1 - BOLTS
Install seven (7) valve body-to-case bolts (1) and torque to 12 N.m (105 in. lbs.). See Fig 49.

Fig 50: Removing/Installing Transmission Filter
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1 - TRANSMISSION FILTER
Install transmission oil filter (1). See Fig 50. Tighten the bolts to 5 N.m (45 in. lbs.).

Fig 51: Removing/Installing Transmission Oil Pan
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1 - TRANSMISSION OIL PAN

Install transmission oil pan (1) with a bead of Mopar® ATF RTV. See Fig 51.

Fig 52: Locating Oil Pan Bolts & Pressure Ports

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1 - FRONT DRIVESHAFT

2 - PRESSURE PORTS

3 - TRANSMISSION CASE

4 - TRANSMISSION OIL PAN

5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE

6 - FIRST TRANSMISSION OIL PAN BOLT

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

Install and torque the oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.).

Fig 53: Locating Input Speed, Output Speed and Transmission Range Sensors

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1 - INPUT SPEED SENSOR

2 - OUTPUT SPEED SENSOR

3 - TRANSMISSION RANGE SENSOR

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 (1, 2) into the transmission case. Torque the speed sensor bolts to 9 N.m (80 in. lbs.). See Fig 53.

Fig 54: Measuring Input Shaft End Play Using End Play Set 8266

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

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. See Fig 54. 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.

On 4X2 transmissions, perform the following, if necessary:

Fig 55: Removing/Installing Extension Shaft Bearing

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1 - EXTENSION SHAFT

2 - BEARING

Install the extension shaft bearing (2) onto the extension shaft. See Fig 55.

Fig 56: Removing/Installing Extension Shaft Bearing Retaining Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - RETAINING RING

Install the extension shaft bearing retaining ring (3) onto the extension shaft (1). See Fig 56.

Fig 57: Removing/Installing Extension Shaft and Bearing Assembly

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1 - EXTENSION HOUSING

2 - EXTENSION SHAFT

3 - BEARING

Install the extension shaft (2) and bearing assembly (3) into the extension housing (1). See Fig 57.

Fig 58: Removing/Installing Extension Shaft Bearing Snap Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - SNAP RING

Install the extension shaft bearing snap ring (3) into the extension housing. See Fig 58.

Fig 59: Extension Shaft Bearing Snap Ring Installed

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1 - EXTENSION SHAFT

2 - BEARING

3 - SNAP RING

Verify that the extension shaft snap ring (3) is fully engaged in the snap ring groove. See Fig 59.

Fig 60: Lube Tube Grommet

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1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

Inspect the lube tube grommet (2) for damage. If the grommet lip is damaged, it will need to be replaced. See Fig 60.

Fig 61: Removing/Installing Adapter Housing
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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING
Install the 4X4 stub shaft onto the transmission output shaft.
Place a bead of Mopar® ATF RTV on the rear surface of the transmission case for the adapter/extension housing.
Install the adapter housing (2) onto the transmission case, 4X4 vehicles only. See Fig 61.

Fig 62: Removing/Installing Extension Housing
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1 - TRANSMISSION CASE

2 - EXTENSION HOUSING

Install the extension housing (2) onto the transmission case, 4X2 vehicles only. See Fig 62.

Fig 63: Adapter Housing Fasteners

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1 - STUD, ADAPTER/EXTENSION

2 - TRANSMISSION MOUNT FASTENERS (4)

3 - TRANSMISSION MOUNT

4 - TRANSMISSION CASE

5 - NUT, EXHAUST HANGER BRACKET (2)

6 - STUD, ADAPTER/EXTENSION

7 - TRANSMISSION OIL PAN

8 - BOLT, ADAPTER/EXTENSION (2)

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

Fig 64: Removing/Installing Adapter Housing Bolts

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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

3 - BOLTS

Install the bolts 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.). See Fig 64.