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

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 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) .

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.

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

Fig 1: Remove Torque Converter

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1 - TORQUE CONVERTER

2 - TRANSMISSION

3 - INPUT SHAFT

Remove the torque converter (1) from the transmission input shaft (3). See Fig 1.

Fig 2: 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 input shaft end play using Tool 8266 (1, 2). Set up Tool 8266 and a dial indicator as shown. See 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 3: Removing/Installing Adapter Housing Bolts

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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

3 - BOLTS

NOTE: The four bolts (3) along the bottom of the adapter or extension housing (2) have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.

Remove the bolts that hold the adapter or extension housing (2) onto the transmission case. See Fig 3.

Fig 4: Removing/Installing Adapter Housing
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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING
Remove the adapter (2) housing, 4X4 vehicles only, from the transmission case. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case. See Fig 4.

Fig 5: Removing/Installing Extension Housing
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1 - TRANSMISSION CASE

2 - EXTENSION HOUSING

Remove the extension (2) housing, 4X2 vehicles only, from the transmission case. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case. See Fig 5.

Fig 6: Lube Tube Grommet

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1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

Inspect the lube tube grommet (3) for damage. If the grommet lip is damaged, it will need to be replaced. See Fig 6.

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

Fig 7: Removing/Installing Extension Shaft Bearing Snap Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - SNAP RING

Remove the extension shaft bearing snap ring (3) from the extension housing. See Fig 7.

Fig 8: Removing/Installing Extension Shaft and Bearing Assembly

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1 - EXTENSION HOUSING

2 - EXTENSION SHAFT

3 - BEARING

Remove the extension shaft and bearing assembly (2) from the extension housing (1). See Fig 8.

Fig 9: Removing/Installing Extension Shaft Bearing Retaining Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - RETAINING RING

Remove the extension shaft bearing retaining ring (3) from the extension shaft (1). See Fig 9.

Fig 10: Removing/Installing Extension Shaft Bearing

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1 - EXTENSION SHAFT

2 - BEARING

Remove the extension shaft bearing (2) from the extension shaft (1). See Fig 10.

Fig 11: Remove the 4X4 Stub Shaft Using C-3752

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1 - 4X4 STUB SHAFT

2 - PULLER C-3752

Using a Slide Hammer C-3752 (2), remove the 4X4 stub shaft (1). See Fig 11.

Fig 12: Remove 4X4 Stub Shaft
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1 - STUB SHAFT

2 - OUTPUT SHAFT
Remove the 4X4 stub shaft (1) from the transmission output shaft. Inspect the cir-clip on the shaft for damage and replace the clip if necessary. See Fig 12.

Fig 13: Remove Input Speed Sensor Bolt
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1 - INPUT SPEED SENSOR

2 - TRANSMISSION CASE

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
Remove the input speed sensor bolt. See Fig 13

Fig 14: Remove Output Speed Sensor Bolt
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
Remove the output speed sensor bolt. See Fig 14

Fig 15: Remove Output Speed Sensor
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the input and output (2) speed sensors. Identify the speed sensors for re-installation since they are not interchangeable. See Fig 15.

Fig 16: Removing/Installing Transmission Oil Pan Bolts
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1 - TRANSMISSION OIL PAN

2 - BOLTS

NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.
Remove the transmission oil pan bolts (2). See Fig 16.

Fig 17: Removing/Installing Transmission Oil Pan
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1 - TRANSMISSION OIL PAN
Remove the transmission oil pan (1). See Fig 17.

Fig 18: Remove Oil Filter Screws
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1 - OIL FILTER

2 - SCREWS
Remove the transmission oil filter screws (2). See Fig 18.

Fig 19: Removing/Installing Transmission Filter
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1 - TRANSMISSION FILTER
Remove transmission oil filter (1). See Fig 19.

Fig 20: Remove Oil Filter O-Ring
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1 - VALVE BODY

2 - O-RING
Remove the oil filter o-ring (2) from the valve body. See Fig 20.

Fig 21: Removing/Installing Valve Body Bolts
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1 - BOLTS
Remove valve body-to-case bolts (1). See Fig 21.

Fig 22: 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.
Remove valve body (1) from transmission. See Fig 22.

Fig 23: Underdrive and Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Remove underdrive and overdrive accumulators (1, 2). See Fig 23.

Fig 24: Removing/Installing Low/Reverse Accumulator Snap Ring
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Remove the low/reverse accumulator snap ring (1). See Fig 24.

Fig 25: Removing/Installing Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Remove the low/reverse accumulator plug (2). See Fig 25.

Fig 26: Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON
Remove low/reverse accumulator piston (1) using suitable pliers. See Fig 26.

Fig 27: Low/Reverse Accumulator
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1 - PISTON

2 - RETURN SPRINGS
Remove piston (1) and springs (2). See Fig 27.

Fig 28: Removing/Installing Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP
Remove and discard the oil pump-to-case bolts (1). See Fig 28. The oil pump bolts are not to be reused.

Fig 29: Oil Pump Pullers
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1 - OIL PUMP

2 - PULLERS
Remove oil pump using C-3752 Pullers (2). See Fig 29.

Fig 30: Remove Oil Pump
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
Remove oil pump while pushing in on input shaft (1). See Fig 30.

Fig 31: Removing/Installing Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Remove oil pump gasket (2). See Fig 31.

Fig 32: Removing/Installing By-Pass Valve
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1 - BYPASS VALVE

CAUTION: By-pass valve must be replaced if transmission failure occurs.
Remove the cooler by-pass valve (1). See Fig 32.

Fig 33: Removing/Installing No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove the #1 caged needle bearing (1). See Fig 33.

Fig 34: Removing/Installing Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY

Remove the input clutch assembly (1). See Fig 34.

Fig 35: Removing/Installing #4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Remove the #4 thrust plate (2). See Fig 35.

Fig 36: Removing/Installing Front Sun Gear Assembly
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Remove the front sun gear assembly (1) and #4 thrust washer (if still in place). See Fig 36.

Fig 37: 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).

Remove the front carrier/rear annulus (2) and #6 needle bearing (1). See Fig 37.

Fig 38: Removing/Installing Rear Sun Gear
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Remove the rear sun gear (2) and #7 needle bearing (1). See Fig 38.

Fig 39: Locating Rear Sun Gear & No. 7 Needle Bearing

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1 - #7 BEARING

2 - REAR SUN GEAR

NOTE: The number seven needle bearing (1) 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear. See Fig 39.

Fig 40: 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.

Install and load Tool 5058A to remove the 2/4 clutch retainer snap ring (3). See Fig 40.

Fig 41: 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

2 - 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.
Remove the 2/4 clutch retainer (1). See Fig 41.

Fig 42: Removing/Installing 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch return spring (1). See Fig 42.

Fig 43: Removing/Installing 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

Remove the 2/4 clutch pack (1, 2). See Fig 43.

Fig 44: Remove Tapered Snap Ring

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1 - LOW/REVERSE CLUTCH REACTION PLATE

2 - LONG TAB

3 - SCREWDRIVER

4 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)

5 - OIL PAN FACE

Remove the tapered snap ring (4). See Fig 44.

Fig 45: Removing/Installing Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove the low/reverse reaction plate (1). See Fig 45.

Fig 46: Removing/Installing One Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove one (1) low/reverse clutch disc to facilitate snap ring removal. See Fig 46

Fig 47: 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

Remove the low/reverse reaction plate snap ring (2). See Fig 47.

Fig 48: Removing/Installing Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Remove the low/reverse clutch pack (1, 2). See Fig 48.

Fig 49: Grinding Stakes

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1 - OUTPUT SHAFT

2 - GRIND HERE

3 - GRIND HERE

4 - NUT STAKE

CAUTION: Failure to grind and open stakes (4) of the output shaft nut will result in thread damage to the shaft during nut removal. See Fig 49.

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.

Fig 50: Stake Grinding Pattern

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1 - OUTPUT SHAFT

2 - OUTPUT SHAFT NUT

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut (2) as shown. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut. See Fig 50.

Fig 51: Opening Nut Stakes
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1 - CHISEL

2 - NUT STAKE

Using a small chisel (1), carefully open the stakes on nut (2). See Fig 51.

Fig 52: Remove Output Shaft Nut

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1 - SPECIAL TOOL 6497

2 - SPECIAL TOOL 6498A

3 - BREAKER BAR

Use special tool 6497 (1) and 6498A (2) to remove the output shaft nut. See Fig 52.

Fig 53: Use Arbor Press to Remove Output Shaft from Case

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1 - OUTPUT SHAFT

2 - ARBOR PRESS

3 - TRANSMISSION CASE

Remove the output shaft (1) from case (3) using a shop press (2). See Fig 53.

Fig 54: Remove Front Bearing Cup - Typical
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1 - ARBOR PRESS

2 - SPECIAL TOOL 6596
Use special tool 6596 (2) with a shop press (1) to remove the front output shaft bearing cup. See Fig 54.

Fig 55: Remove Rear Bearing Cup
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1 - SPECIAL TOOL 4171 AND 4171-2

2 - SPECIAL TOOL 6597

Use special tool 6597 (2) and handle C-4171 (1) and C-4171-2 to press the rear output shaft bearing cup rearward. See Fig 55.

Fig 56: Remove Rear Carrier Front Bearing Cone

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1 - SPECIAL TOOL 5048-1

2 - SPECIAL TOOL 6545

3 - REAR CARRIER

4 - SPECIAL TOOL 5048

Remove the rear carrier front bearing cone (3). See Fig 56.

Fig 57: 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 compressor 5059A (4) as shown. See Fig 57.

Fig 58: Remove Snap Ring

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

2 - SNAP RING PLIERS

3 - SPECIAL TOOL 5059A

Remove the low/reverse belleville spring snap ring (1). See Fig 58.

Fig 59: Removing/Installing Low/Reverse Piston Belleville Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON
Remove the low/reverse piston belleville spring (1). See Fig 59.

Fig 60: Anchor Shaft Removal
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1 - PIN PUNCH

2 - GUIDE BRACKET ASSEMBLY
Remove the park sprag pivot retaining screw.
Drive out the anchor shaft using suitable punch (1). See Fig 60.

Fig 61: Removing/Installing Guide Bracket Pivot Shaft
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

Remove the guide bracket pivot pin (1). See Fig 61. Inspect all components for wear and replace if necessary.

Fig 62: 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.

Remove the low/reverse clutch piston (1). See Fig 62.
Remove the low/reverse piston retainer screws.

Fig 63: Removing/Installing Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer (1). See Fig 63.

Fig 64: Removing/Installing Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Remove the low/reverse piston retainer gasket (2). See Fig 64.