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Overhaul - 42RLE Automatic Transmission: Assembly

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.
  1. Install the output bearing cups using Special Tool - 5050A.
    Fig 1: Identifying Bearing Cup Installation Special Tool 5050A
    G01707647Courtesy of DAIMLERCHRYSLER CORP.
  2. Install low/reverse piston retainer gasket.
    Fig 2: Installing Piston Retainer Gasket
    G01707648Courtesy of DAIMLERCHRYSLER CORP.
  3. Install low/reverse piston retainer.
    Fig 3: Installing Piston Retainer
    G01707649Courtesy of DAIMLERCHRYSLER CORP.
  4. Install low/reverse piston retainer-to-case screws and torque to 5 N.m (45 in. lbs.).
    Fig 4: Installing Retainer Attaching Screws
    G01707650Courtesy of DAIMLERCHRYSLER CORP.
    5. NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
  5. Install low/reverse clutch piston.
    6. Fig 5: Installing Low/Reverse Clutch Piston
    G01707651Courtesy of DAIMLERCHRYSLER CORP.
  6. Assemble guide bracket assembly as shown.
    Fig 6: Assembling Guide Bracket
    G01707652Courtesy of DAIMLERCHRYSLER CORP.
    Fig 7: Installing Guide Bracket
    G01707653Courtesy of DAIMLERCHRYSLER CORP.
  7. Install guide bracket pivot shaft.
    Fig 8: Installing Guide Bracket Pivot Shaft
    G01707654Courtesy of DAIMLERCHRYSLER CORP.
    8. CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case.
  8. Install park sprag pivot retaining screw and torque to 4.5 N.m (40 in. lbs.).
  9. Install low/reverse piston belleville spring into position.
    Fig 9: Installing Low/Reverse Piston Return Spring
    G01707655Courtesy of DAIMLERCHRYSLER CORP.
  10. Install and load low/reverse spring compressor tool as shown to facilitate snap ring installation.
    Fig 10: Installing Low/Reverse Spring Compressor Tool
    G01707656Courtesy of DAIMLERCHRYSLER CORP.
    Fig 11: Using Compressor Tool
    G01707657Courtesy of DAIMLERCHRYSLER CORP.
  11. Install snap ring and remove compressor tool.
    Fig 12: Installing Snap Ring
    G01707658Courtesy of DAIMLERCHRYSLER CORP.
  12. Install rear carrier front bearing cone.
    Fig 13: Installing Rear Carrier Front Bearing Cone
    G01707659Courtesy of DAIMLERCHRYSLER CORP.
  13. 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. 92).
        Fig 14: Installing Bearing
        G01707660Courtesy of DAIMLERCHRYSLER CORP.
      2. Install special tool 6618A (Fig. 93). Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
        Fig 15: Installing Special Tool 6618A
        G01707661Courtesy 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. 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 16: Installing Shim
        G01707662Courtesy 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 17: Pressing Shaft Into Case
        G01707663Courtesy 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. Do not reuse old output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.)
      7. Check the turning torque of the output shaft. 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 18: Checking Turning Torque
        G01707664Courtesy of DAIMLERCHRYSLER CORP.
        8. CAUTION: Failure to stake nut could allow the nut to back-off during use.
        Fig 19: Staking Output Shaft Nut (Typical)
        G01707665Courtesy of DAIMLERCHRYSLER CORP.
        Fig 20: Identifying Properly Staked Nut
        G01707666Courtesy of DAIMLERCHRYSLER CORP.
      8. The new nut must be staked after the correct turning torque is obtained. Use special tool 6639 to stake output shaft nut.
  14. Install low/reverse clutch pack. Leave uppermost disc out to facilitate snap ring installation.
    Fig 21: Installing Low/Reverse Clutch Pack
    G01707667Courtesy of DAIMLERCHRYSLER CORP.
  15. Install low/reverse reaction plate snap ring.
    Fig 22: Installing Low/Reverse Reaction Plate Snap Ring
    G01707668Courtesy of DAIMLERCHRYSLER CORP.
  16. Install one low/reverse clutch disc.
    Fig 23: Installing One Low/Reverse Clutch Disc
    G01707669Courtesy of DAIMLERCHRYSLER CORP.
  17. Install low/reverse reaction plate with flat side up.
    Fig 24: Installing Low/Reverse Reaction Plate
    G01707670Courtesy of DAIMLERCHRYSLER CORP.
  18. Install a new tapered snap ring (tapered side out). Make sure that the snap ring ends are oriented as shown.
    Fig 25: Installing Snap Ring
    G01707671Courtesy of DAIMLERCHRYSLER CORP.
    Fig 26: Identifying Tapered Snap Ring Instructions
    G01707672Courtesy of DAIMLERCHRYSLER CORP.
  19. Measure low/reverse clutch pack. Set up dial indicator as shown. 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 27: Checking Low/Reverse Clutch Clearance
    G01707673Courtesy of DAIMLERCHRYSLER CORP.
  20. Select the proper low/reverse reaction plate to achieve specifications.
  21. Install 2/4 clutch pack.
    Fig 28: Installing 2/4 Clutch Pack
    G01707674Courtesy of DAIMLERCHRYSLER CORP.
    22. NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
    Fig 29: Installing 2/4 Clutch Return Spring
    G01707675Courtesy of DAIMLERCHRYSLER CORP.
    Fig 30: Identifying Proper Orientation Of 2/4 Clutch
    G01707676Courtesy of DAIMLERCHRYSLER CORP.
  22. Install 2/4 clutch belleville spring.
  23. Install 2/4 clutch retainer.
    Fig 31: Installing 2/4 Clutch Retainer
    G01707677Courtesy of DAIMLERCHRYSLER CORP.
    24. 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.
    Fig 32: Installing 2/4 Clutch Retainer Snap Ring
    G01707678Courtesy of DAIMLERCHRYSLER CORP.
  24. Set up Tool 5058 as shown. Compress 2/4 clutch just enough to facilitate snap ring installation.
  25. Measure 2/4 clutch clearance:  Set up dial indicator as shown. 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 33: Checking 2/4 Clutch Clearance
    G01707679Courtesy of DAIMLERCHRYSLER CORP.
  26. Install the #7 needle bearing to the rear sun gear. 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 34: Installing No. 7 Bearing
    G01707680Courtesy of DAIMLERCHRYSLER CORP.
  27. Install rear sun gear and #7 needle bearing.
    Fig 35: Installing Rear Sun Gear
    G01707681Courtesy of DAIMLERCHRYSLER CORP.
  28. Install front carrier/rear annulus assembly and #6 needle bearing.
    Fig 36: Installing Front Carrier/Rear Annulus
    G01707682Courtesy of DAIMLERCHRYSLER CORP.
  29. Install front sun gear assembly and #4 thrust washer.
    Fig 37: Installing Front Sun Gear Assembly
    G01707683Courtesy of DAIMLERCHRYSLER CORP.
  30. Determine proper #4 thrust plate thickness. 
    1. Select the thinnest #4 thrust plate thickness.
    2. Install #4 thrust plate using petrolatum to hold into position.
      Fig 38: Installing No. 4 Thrust Plate
      G01707684Courtesy of DAIMLERCHRYSLER CORP.
    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 clutch assembly is not seated properly. 
    4. Remove the oil pump o-ring and install oil pump and gasket to transmission. Tighten the oil pump bolts to 30 N.m (265 in. lbs.). Use screw-in dowels or phillips-head screw-drivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate. 
      Fig 39: Removing Oil Pump O-Ring
      G01707685Courtesy 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.
      Fig 40: Measuring Input Shaft End Play Using Tool 8266 (Typical)
      G01707686Courtesy 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.
  31. Install input clutch assembly with proper thrust plate.
    Fig 41: Installing Input Clutch Assembly
    G01707687Courtesy of DAIMLERCHRYSLER CORP.
  32. Install #1 caged needle bearing.
    Fig 42: Installing No. 1 Caged Needle Bearing
    G01707688Courtesy of DAIMLERCHRYSLER CORP.
    33. CAUTION: By-pass valve MUST be replaced if transmission failure occurs.
    Fig 43: Installing By-Pass Valve
    G01707689Courtesy of DAIMLERCHRYSLER CORP.
  33. Replace cooler by-pass valve if transmission failure has occurred.
    34. NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.
    Fig 44: Installing Oil Pump Gasket
    G01707690Courtesy of DAIMLERCHRYSLER CORP.
  34. Install oil pump gasket.
  35. Install oil pump and torque the new oil pump-to-case bolts to 30 N.m (265 in. lbs.). Do not reuse original oil pump bolts.
    Fig 45: Installing Oil Pump Attaching Bolts
    G01707691Courtesy of DAIMLERCHRYSLER CORP.
  36. Install low/reverse accumulator as shown.
    Fig 46: Installing Low/Reverse Accumulator
    G01707692Courtesy of DAIMLERCHRYSLER CORP.
  37. Install low/reverse accumulator plug.
    Fig 47: Installing Low/Reverse Accumulator Plug
    G01707693Courtesy of DAIMLERCHRYSLER CORP.
  38. Install low/reverse accumulator snap ring.
    Fig 48: Installing Low/Reverse Accumulator Snap Ring
    G01707694Courtesy of DAIMLERCHRYSLER CORP.
  39. Install underdrive and overdrive accumulators and springs.
    Fig 49: Installing Underdrive & Overdrive Accumulators
    G01707695Courtesy of DAIMLERCHRYSLER CORP.
    40. CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
    Fig 50: Installing Valve Body Onto Transmission
    G01707696Courtesy of DAIMLERCHRYSLER CORP.
  40. Install valve body into place as shown.
  41. Install seven (7) valve body-to-case bolts and torque to 12 N.m (105 in. lbs.).
    Fig 51: Installing Valve Body Bolts (7)
    G01707697Courtesy of DAIMLERCHRYSLER CORP.
  42. Install transmission oil filter. Tighten the bolts to 5 N.m (45 in. lbs.)
    Fig 52: Installing Transmission Filter
    G01707698Courtesy of DAIMLERCHRYSLER CORP.
    43. NOTE: Before installing the oil pan bolt in the bolt table 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.
    Fig 53: Locating Pan Fasteners
    G01707699Courtesy of DAIMLERCHRYSLER CORP.
    Fig 54: Installing Transmission Oil Pan
    G01707700Courtesy of DAIMLERCHRYSLER CORP.
  43. Install transmission oil pan with a bead of Mopar® ATF RTV. Torque oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.).
    44. NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock & Seal Adhesive.
    Fig 55: Installing Input & Output Speed Sensors & Transmission Range Sensor
    G01707701Courtesy of DAIMLERCHRYSLER CORP.
  44. Install both speed sensors into transmission case. Torque the speed sensor bolts to 9 N.m (80 in. lbs.).
  45. 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. 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 56: Measuring Input Shaft End Play Using Tool 8266 (Typical)
    G01707702Courtesy of DAIMLERCHRYSLER CORP.
  46. Inspect the lube tube grommet for damage. If the grommet lip is damaged, it will need to be replaced.
    Fig 57: Inspecting Lube Tube Grommet
    G01707703Courtesy of DAIMLERCHRYSLER CORP.
  47. Install the 4X4 stub shaft onto the transmission output shaft.
  48. Place a bead of Mopar® ATF RTV on the rear surface of the transmission case for the adapter housing.
  49. Install the adapter housing onto the transmission case.
    Fig 58: Installing Adapter Housing
    G01707704Courtesy of DAIMLERCHRYSLER CORP.
    50. NOTE: Before installing the lowermost four adapter housing bolts (Fig. 137), it will be necessary to replenish the sealing patch on the bolts using Mopar® Lock & Seal Adhesive.
    Fig 59: Locating Adapter Housing Fasteners
    G01707705Courtesy of DAIMLERCHRYSLER CORP.
  50. Install the bolts that hold the adapter 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.).
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