Overhaul - 42RLE Automatic Transmission: Disassembly

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

1. Remove the torque converter from the transmission input shaft.
   Fig 1: Removing Torque Converter

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2. Measure input shaft end play using Tool 8266. Set up Tool 8266 and a dial indicator as shown. 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 (Typical)

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NOTE: The four bolts along the bottom of the adapter housing have a sealing patch applied from the factory. Note the locations of these bolts and seperate these bolts for reuse.
Fig 3: Removing Adapter Housing Bolts
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3. Remove the bolts that hold the adapter housing onto the transmission case.
4. Remove the adapter (Fig. 21) housing from the transmission case. There are two pry slots (Fig. 20) located near the bottom corners of the housing for separating the housing from the transmission case.
   Fig 4: Locating Lube Tube Grommet

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   Fig 5: Removing Adapter Housing

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5. Inspect the lube tube grommet for damage. See Fig 4. If the grommet lip is damaged, it will need to be replaced.
6. Using a Slide Hammer C-3752, remove the 4X4 stub shaft (Fig. 23) from the transmission output shaft. Inspect the circlip on the shaft for damage and replace the clip if necessary.
   Fig 6: Removing 4X4 Stub Shaft Using C-3752

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   Fig 7: Removing 4X4 Stub Shaft

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7. Remove the input speed sensor bolt.
   Fig 8: Removing Input Speed Sensor Bolt

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NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
Fig 9: Removing Output Speed Sensor Bolt
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8. Remove the output speed sensor bolt.
9. Remove the input and output speed sensors. Identify the speed sensors for re-installation since they are not interchangeable.
   Fig 10: Removing Output Speed Sensor

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NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.
10. Remove the transmission oil pan bolts.
Fig 11: Removing Transmission Oil Pan Bolts
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11. Remove the transmission oil pan.
    Fig 12: Removing Transmission Oil Pan

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12. Remove the transmission oil filter screws.
    Fig 13: Removing Oil Filter Screws

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13. Remove transmission oil filter.
    Fig 14: Removing Transmission Filter

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14. Remove the oil filter o-ring from the valve body.
    Fig 15: Removing Oil Filter O-Ring

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15. Remove valve body-to-case bolts.
    Fig 16: Removing Valve Body Bolts

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CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Fig 17: Removing Valve Body From Transmission
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16. Remove valve body from transmission.
17. Remove underdrive and overdrive accumulators.
    Fig 18: Removing Underdrive & Overdrive Accumulators

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18. Remove the low/reverse accumulator snap ring.
    Fig 19: Removing Low/Reverse Accumulators

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19. Remove the low/reverse accumulator plug.
    Fig 20: Removing Low/Reverse Accumulator Plug

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20. Remove low/reverse accumulator piston using suitable pliers. Remove piston and springs.
    Fig 21: Removing Low/Reverse Accumulator Piston

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    Fig 22: Removing Low/Reverse Accumulator

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21. Remove and discard the oil pump-to-case bolts. The oil pump bolts are not to be reused.
    Fig 23: Removing Oil Pump Attaching Bolts

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22. Remove oil pump using C-3752 Pullers.
    Fig 24: Removing Oil Pump Pullers

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23. Remove oil pump while pushing in on input shaft.
    Fig 25: Removing Oil Pump

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24. Remove oil pump gasket.
    Fig 26: Removing Oil Pump Gasket

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CAUTION: By-pass valve must be replaced if transmission failure occurs.
Fig 27: Removing By-Pass Valve
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25. Remove the cooler by-pass valve.
26. Remove the #1 caged needle bearing.
    Fig 28: Removing No. 1 Caged Needle Bearing

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27. Remove the input clutch assembly.
    Fig 29: Removing Input Clutch Assembly

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28. Remove the #4 thrust plate.
    Fig 30: Removing No. 4 Thrust Plate

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29. Remove the front sun gear assembly and #4 thrust washer (if still in place).
    Fig 31: Removing Front Sun Gear Assembly

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30. Remove the front carrier/rear annulus and #6 needle bearing.
    Fig 32: Removing Front Carrier/Rear Annulus

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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. 50).
Fig 33: Removing Rear Sun Gear
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Fig 34: Removing No. 7 Bearing
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31. Remove the rear sun gear and #7 needle bearing.
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 35: Removing 2/4 Clutch Retainer Snap Ring
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32. Install and load Tool 5058A to remove the 2/4 clutch retainer snap ring.
NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Fig 36: Removing 2/4 Clutch Retainer Snap Ring
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Fig 37: Removing 2/4 Clutch Retainer
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33. Remove the 2/4 clutch retainer.
34. Remove the 2/4 clutch return spring.
    Fig 38: Removing 2/4 Clutch Return Spring

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CAUTION: TAG AND IDENTIFY CLUTCH PACKS TO ASSURE ORIGINAL PLACEMENT
Fig 39: Removing 2/4 Clutch Pack
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35. Remove the 2/4 clutch pack.
36. Remove the tapered snap ring.
    Fig 40: Removing Tapered Snap Ring

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37. Remove the low/reverse reaction plate (Fig. 57).
    Fig 41: Removing Low/Reverse Reaction Plate

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38. Remove one (1) low/reverse clutch disc to facilitate snap ring removal.
    Fig 42: Removing One Disc From Low/Reverse Clutch

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39. Remove the low/reverse reaction plate snap ring.
    Fig 43: Removing Low/Reverse Reaction Plate Snap Ring

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CAUTION: TAG AND IDENTIFY PACKS TO ASSURE ORIGINAL PLACEMENT.
Fig 44: Removing Low/Reverse Clutch Pack
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40. Remove the low/reverse clutch pack.
WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.
CAUTION: Failure to grind and open stakes of the output shaft nut will result in thread damage to the shaft during nut removal.
Fig 45: Grinding Stakes
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Fig 46: Identifying Stake Grinding Pattern
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41. Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
42. Using a small chisel, carefully open the stakes on nut.
    Fig 47: Opening Nut Stakes

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43. Use special tool 6497 and 6498A to remove the transfer shaft nut or the output shaft nut.
    Fig 48: Removing Output Shaft Nut

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44. Remove the output shaft from case using a shop press.
    Fig 49: Using Arbor Press To Remove Output Shaft From Case

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    Use special tool 6596 with a shop press to remove the front output shaft bearing cup (Fig. 66).

    Fig 50: Removing Front Bearing Cup (Typical)

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45. Use special tool 6597 and handle C-4171 and C-4171-2 to press the rear output shaft bearing cup rearward.
    Fig 51: Removing Rear Bearing Cup

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46. Remove the rear carrier front bearing cone.
    Fig 52: Removing Rear Carrier Front Bearing Cone

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47. Install and load compressor as shown.
    Fig 53: Installing Low/Reverse Spring Compressor Tool

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    Fig 54: Using Compressor Tool

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48. Remove the low/reverse belleville spring snap ring (Fig. 71).
    Fig 55: Removing Snap Ring

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49. Remove the low/reverse piston belleville spring.
    Fig 56: Removing Low/Reverse Piston Belleville Spring

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50. Remove the park sprag pivot retaining screw.
51. Drive out the anchor shaft using suitable punch.
    Fig 57: Removing Anchor Shaft

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52. Remove the guide bracket pivot shaft. Inspect all components for wear and replace if necessary.
    Fig 58: Removing Guide Bracket Pivot Shaft

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    Fig 59: Identifying Guide Bracket Disassembled

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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.
Fig 60: Removing Low/Reverse Clutch Piston
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53. Remove the low/reverse clutch piston.
54. Remove the low/reverse piston retainer screws.
55. Remove low/reverse piston retainer.
    Fig 61: Removing Piston Retainer

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56. Remove the low/reverse piston retainer gasket.
    Fig 62: Removing Piston Retainer Gasket

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