42RLE - Service Information: 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. (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) .

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

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2. Install low/reverse piston retainer gasket. See Fig 2.
   Fig 2: Removing/Installing Piston Retainer Gasket

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   1 - GASKET HOLES MUST LINE UP

   2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

3. Install low/reverse piston retainer. See Fig 3.
   Fig 3: Removing/Installing Piston Retainer

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   1 - LOW/REVERSE CLUTCH PISTON RETAINER

   2 - GASKET

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

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   1 - LOW/REVERSE CLUTCH PISTON RETAINER

   2 - SCREWDRIVER

   3 - TORX-LOC SCREWS

   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. See Fig 5.
   Fig 5: Removing/Installing Low/Reverse Clutch Piston

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   1 - LOW/REVERSE CLUTCH PISTON

   2 - BONDED SEAL

   3 - BONDED SEAL

6. Assemble guide bracket assembly as shown in Fig 6 and Fig 7.
   Fig 6: Guide Bracket Assembly

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   1 - GUIDE BRACKET

   2 - PAWL

   3 - SPLIT SLEEVE

   4 - SPACER

   5 - STEPPED SPACER

   6 - ANTI-RATCHET SPRING

   Fig 7: Assembled Guide Bracket

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   1 - GUIDE BRACKET

   2 - ANTI-RATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)

   3 - PAWL

7. Install guide bracket pivot shaft. See Fig 8.
   Fig 8: Removing/Installing Guide Bracket Pivot Pin

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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.
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. See Fig 9.
   Fig 9: Removing/Installing Low/Reverse Piston Belleville Spring

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   1 - LOW/REVERSE PISTON RETURN SPRING

   2 - PISTON

10. Install and load low/reverse spring compressor tool as shown in Fig 10 and Fig 11, to facilitate snap ring installation.
    Fig 10: Low/Reverse Spring Compressor Tool

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    1 - DISC 6057

    2 - COMPRESSOR 5059

    3 - COMPRESSOR 5058-3

    Fig 11: Compressor Tool In Use

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    1 - LOW/REVERSE CLUTCH RETURN SPRING

    2 - SNAP RING (INSTALL AS SHOWN)

    3 - COMPRESSOR 5058A-3

    4 - COMPRESSOR 5059A

    5 - DISC 6057

11. Install snap ring and remove compressor tool. See Fig 12.
    Fig 12: Installing Low/Reverse Clutch Snap Ring

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

    2 - SNAP RING PLIERS

    3 - TOOL 6057

12. Install rear carrier front bearing cone. See Fig 13.
    Fig 13: Installing Rear Carrier Front Bearing Cone

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    1 - ARBOR PRESS

    2 - SPECIAL TOOL C-4171

    3 - SPECIAL TOOL 6052

    4 - REAR CARRIER

13. 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. See Fig 14.
    • Install special tool 6618A. See Fig 15. 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. 
    • Install shim on output shaft. See Fig 16. 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.
    • 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. See Fig 17.
    • Do not reuse 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.).
    • Check the turning torque of the output shaft. See Fig 18. 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.
    • The new nut must be staked after the correct turning torque is obtained. See Fig 19. See Fig 20. Use special tool 6639 to stake output shaft nut. CAUTION: Failure to stake nut could allow the nut to back-off during use. 
    Fig 14: Installing Bearing And Support Plate

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    1 - SPECIAL TOOL 6618-A

    2 - REAR OUTPUT SHAFT BEARING

    Fig 15: Installing Support Plate

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    1 - SPECIAL TOOL 6618-A

    Fig 16: Shim Installation

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    1 - SHIM

    2 - OUTPUT SHAFT

    Fig 17: Pressing Shaft Into Rear Bearing

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    1 - SPECIAL TOOL C-4171 AND C-4171-2

    2 - SPECIAL TOOL MD-998911

    Fig 18: Checking Turning Torque Of Output Shaft

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    1 - TORQUE WRENCH

    2 - SPECIAL TOOL 6498-A

    3 - OUTPUT SHAFT NUT

    Fig 19: Staking Output Shaft Nut

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    1 - ARBOR PRESS

    2 - STAKING TOOL - 6639

    3 - NEW NUT

    Fig 20: View Of Properly Staked Nut

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    1 - BOTTOMED IN SLOT

    2 - CORRECTLY STAKED NUT

14. Install low/reverse clutch pack. See Fig 21. Leave uppermost disc out to facilitate snap ring installation.
    Fig 21: Removing/Installing Low/Reverse Clutch Pack

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    1 - CLUTCH PLATES (5)

    2 - CLUTCH DISCS (5)

15. Install low/reverse reaction plate snap ring. See Fig 22.
    Fig 22: 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

16. Install one low/reverse clutch disc. See Fig 23.
    Fig 23: Low/Reverse Clutch Disc

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    1 - ONE DISC FROM LOW/REVERSE CLUTCH

17. Install low/reverse reaction plate with flat side up. See Fig 24.
    Fig 24: Removing/Installing Low/Reverse Reaction Plate

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    1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

18. Install a new tapered snap ring (tapered side out). See Fig 25. Make sure that the snap ring ends are oriented as shown. See Fig 26
    Fig 25: Installing Low/Reverse Clutch Snap Ring

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    1 - SCREWDRIVER

    2 - TAPERED SNAP RING (INSTALL AS SHOWN)

    Fig 26: Proper Snap Ring Orientation

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19. Measure low/reverse clutch pack. Set up dial indicator as shown in Fig 27. 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

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    1 - DIAL INDICATOR

    2 - DIAL INDICATOR TIP TOOL 6268

    3 - HOOK TOOL

20. Select the proper low/reverse reaction plate to achieve specifications.
21. Install 2/4 clutch pack. See Fig 28.
    Fig 28: Removing/Installing 2/4 Clutch Pack

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    1 - CLUTCH PLATE (4)

    2 - CLUTCH DISC (4)

    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
22. Install 2/4 clutch Belleville spring. See Fig 29. See Fig 30.
    Fig 29: Removing/Installing 2/4 Clutch Return Spring

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    1 - 2/4 CLUTCH RETURN SPRING

    Fig 30: View Of Proper Orientation Of 2/4 Clutch Retainer And Spring

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    1 - NOTE POSITION

    2 - RETURN SPRING

    3 - 2/4 CLUTCH RETAINER

23. Install 2/4 clutch retainer. See Fig 31.
    Fig 31: Installing 2/4 Clutch Retainer

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    1 - 2/4 CLUTCH RETAINER

    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.
24. Set up Tool 5058 as shown in Fig 32. Compress 2/4 clutch just enough to facilitate snap ring installation.
    Fig 32: Removing/Installing 2/4 Clutch Retainer Snap Ring

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    1 - TOOL 5058

    2 - SCREWDRIVER

    3 - SNAP RING

    4 - 2/4 CLUTCH RETAINER

25. Measure 2/4 clutch clearance:  Set up dial indicator as shown in Fig 33. 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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - DIAL INDICATOR

    2 - HOOK TOOL

    3 - DIAL INDICATOR TIP TOOL 6268

26. Install the #7 needle bearing to the rear sun gear. See Fig 34. The number 7 needle bearing has three anti-reversal 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: Identifying Rear Sun Gear & No. 7 Needle Bearing

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    1 - #7 BEARING

    2 - REAR SUN GEAR

27. Install rear sun gear and #7 needle bearing. See Fig 35.
    Fig 35: View Of Rear Sun Gear And Needle Bearing

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    1 - #7 NEEDLE BEARING

    2 - REAR SUN GEAR

28. Install front carrier/rear annulus assembly and #6 needle bearing. See Fig 36.
    Fig 36: Identifying Front Carrier/Rear Annulus And Needle Bearing

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    1 - #6 NEEDLE BEARING

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

29. Install front sun gear assembly and #4 thrust washer. See Fig 37.
    Fig 37: View Of Front Sun Gear Assembly And #4 Thrust Washer

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    1 - FRONT SUN GEAR ASSEMBLY

    2 - #4 THRUST WASHER (FOUR TABS)

30. Determine proper #4 thrust plate thickness. 
    • Select the thinnest #4 thrust plate thickness.
    • Install #4 thrust plate using petrolatum to hold into position. See Fig 38.
    • 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. 
    • 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.). See Fig 39. 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. 
    • 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 and Dial Indicator Set C3339 as shown in Fig 40.
    • 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.
    • Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
    Fig 38: Identifying #4 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #4 THRUST PLATE (SELECT)

    3 - PETROLATUM FOR RETENTION

    Fig 39: Removing/Installing Oil Pump O-Ring

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    1 - OIL PUMP ASSEMBLY

    2 - O-RING

    Fig 40: 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

31. Install input clutch assembly with proper thrust plate. See Fig 41.
    Fig 41: Removing/Installing Input Clutch Assembly

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    1 - INPUT CLUTCH ASSEMBLY

32. Install #1 caged needle bearing. See Fig 42.
    Fig 42: Removing/Installing No. 1 Caged Needle Bearing

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    1 - #1 CAGED NEEDLE BEARING

    2 - NOTE: TANGED SIDE OUT

33. Replace cooler by-pass valve if transmission failure has occurred. See Fig 43.
    CAUTION: By-pass valve MUST be replaced if transmission failure occurs.
    Fig 43: Identifying Cooler By-Pass Valve

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    1 - BYPASS VALVE

    NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.
34. Install oil pump gasket. See Fig 44.
    Fig 44: Identifying Oil Pump Gasket

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    1 - BELLHOUSING

    2 - OIL PUMP GASKET

35. Install oil pump and torque the new oil pump-to-case bolts to 30 N.m (265 in. lbs.). See Fig 45. Do not reuse original oil pump bolts.
    Fig 45: Removing/Installing Oil Pump Attaching Bolts

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - BOLTS

    2 - OIL PUMP

36. Install low/reverse accumulator as shown in Fig 46.
    Fig 46: Low/Reverse Accumulator Piston And Springs

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    1 - PISTON

    2 - RETURN SPRINGS

37. Install low/reverse accumulator plug. See Fig 47.
    Fig 47: Removing/Installing Low/Reverse Accumulator Plug

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    1 - ADJUSTABLE PLIERS

    2 - PLUG

38. Install low/reverse accumulator snap ring. See Fig 48.
    Fig 48: Removing/Installing Low/Reverse Accumulator Snap Ring

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    1 - SNAP RING

    2 - LOW/REVERSE ACCUMULATOR

39. Install underdrive and overdrive accumulators and springs. See Fig 49.
    Fig 49: Identifying Underdrive And Overdrive Accumulators

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    1 - OVERDRIVE PISTON AND SPRING

    2 - UNDERDRIVE PISTON AND SPRING

    CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
40. Install valve body into place as shown in Fig 50.
    Fig 50: Removing/Installing Valve Body

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    1 - VALVE BODY

41. Install seven (7) valve body-to-case bolts and torque to 12 N.m (105 in. lbs.). See Fig 51.
    Fig 51: Removing/Installing Valve Body Bolts

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    1 - BOLTS

42. Install transmission oil filter. See Fig 52. Tighten the bolts to 5 N.m (45 in. lbs.)
    Fig 52: Removing/Installing Transmission Filter

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    1 - TRANSMISSION FILTER

    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 53.
    Fig 53: 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

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.). See Fig 54.
    Fig 54: Removing/Installing Transmission Oil Pan

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - TRANSMISSION OIL PAN

    NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock & Seal Adhesive.
44. Install both speed sensors into transmission case. See Fig 55. Torque the speed sensor bolts to 9 N.m (80 in. lbs.).
    Fig 55: 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

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. See Fig 56. 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 End Play Set 8266

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    1 - TOOL 8266-8

    2 - TOOL 8266-2

    3 - TOOL C-3339

46. Inspect the lube tube grommet for damage. If the grommet lip is damaged, it will need to be replaced. See Fig 57.
    Fig 57: Locating Lube Tube & Grommet

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    1 - HOUSING

    2 - LUBE TUBE

    3 - GROMMET

    4 - PRY SLOTS

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. See Fig 58.
    Fig 58: Removing/Installing Adapter Housing

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - TRANSMISSION CASE

    2 - ADAPTER HOUSING

    NOTE: Before installing the lowermost four adapter housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mopar® Lock & Seal Adhesive. See Fig 59.
    Fig 59: 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)

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.). See Fig 60.

Fig 60: Removing/Installing Adapter Housing Bolts

Courtesy of DAIMLERCHRYSLER CORP.

1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

3 - BOLTS