42RLE - Service Information: 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. See Fig 1.
   Fig 1: Removing/Installing Torque Converter

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - TORQUE CONVERTER

   2 - TRANSMISSION

   3 - INPUT SHAFT

2. Measure input shaft end play using End Play Set 8266. Set up the required pieces from End Play Set 8266 and a dial indicator as shown in Fig 2. Move input shaft in and out to obtain end play reading. End play specifications are 0.127 to 0.635 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 End Play Set 8266

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - TOOL 8266-8

   2 - TOOL 8266-2

   3 - TOOL C-3339

   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 separate these bolts for reuse.
3. Remove the bolts that hold the adapter housing onto the transmission case. See Fig 3.
4. Remove the adapter housing 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 and Fig 5.
   Fig 3: Removing/Installing Adapter Housing Bolts

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - TRANSMISSION CASE

   2 - ADAPTER HOUSING

   3 - BOLTS

   Fig 4: Locating Lube Tube & Grommet

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - HOUSING

   2 - LUBE TUBE

   3 - GROMMET

   4 - PRY SLOTS

   Fig 5: Removing/Installing Adapter Housing

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - TRANSMISSION CASE

   2 - ADAPTER HOUSING

5. Inspect the lube tube grommet for damage. If the grommet lip is damaged, it will need to be replaced. See Fig 4.
6. Using a Slide Hammer C-3752, remove the 4X4 stub shaft from the transmission output shaft. Inspect the circlip on the shaft for damage and replace the clip if necessary. See Fig 6 and Fig 7.
   Fig 6: Remove the 4X4 Stub Shaft Using C-3752

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - 4X4 STUB SHAFT

   2 - SLIDE HAMMER C-3752

   Fig 7: Remove 4X4 Stub Shaft

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - STUB SHAFT

   2 - OUTPUT SHAFT

7. Remove the input speed sensor bolt. See Fig 8.
8. Remove the output speed sensor bolt. See Fig 9.
   NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
9. Remove the input and output speed sensors. See Fig 10. Identify the speed sensors for reinstallation since they are not interchangeable.
   Fig 8: Removing/Installing Input Speed Sensor Bolt

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - INPUT SPEED SENSOR

   2 - TRANSMISSION CASE

   Fig 9: Removing/Installing Output Speed Sensor Bolt

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - OUTPUT SPEED SENSOR

   2 - TRANSMISSION CASE

   Fig 10: Removing/Installing Output Speed Sensor

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - OUTPUT SPEED SENSOR

   2 - TRANSMISSION CASE

   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. See Fig 11.
11. Remove the transmission oil pan. See Fig 12.
    Fig 11: Removing/Installing Transmission Oil Pan Bolts

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - TRANSMISSION OIL PAN

    2 - BOLTS

    Fig 12: Removing/Installing Transmission Oil Pan

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - TRANSMISSION OIL PAN

12. Remove the transmission oil filter screws. See Fig 13.
13. Remove transmission oil filter. See Fig 14.
14. Remove the oil filter O-ring from the valve body. See Fig 15.
    Fig 13: Removing/Installing Oil Filter Screws

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - OIL FILTER

    2 - SCREWS

    Fig 14: Removing/Installing Transmission Filter

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - TRANSMISSION FILTER

    Fig 15: Locating Oil Filter O-Ring

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - VALVE BODY

    2 - O-RING

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - BOLTS

    CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
16. Remove valve body from transmission. See Fig 17.
    Fig 17: Removing/Installing Valve Body

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - VALVE BODY

17. Remove underdrive and overdrive accumulators. See Fig 18.
    Fig 18: Identifying Underdrive And Overdrive Accumulators

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - OVERDRIVE PISTON AND SPRING

    2 - UNDERDRIVE PISTON AND SPRING

18. Remove the low/reverse accumulator snap ring. See Fig 19.
    Fig 19: Removing/Installing Low/Reverse Accumulator Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - SNAP RING

    2 - LOW/REVERSE ACCUMULATOR

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - ADJUSTABLE PLIERS

    2 - PLUG

20. Remove low/reverse accumulator piston using suitable pliers. See Fig 21. Remove piston and springs. See Fig 22.
    Fig 21: Low/Reverse Accumulator Piston

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - ACCUMULATOR PISTON

    Fig 22: Low/Reverse Accumulator Piston And Springs

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - PISTON

    2 - RETURN SPRINGS

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - BOLTS

    2 - OIL PUMP

22. Remove oil pump using Slide Hammers C-3752. See Fig 24.
    Fig 24: Removing Oil Pump

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - OIL PUMP

    2 - PULLERS

23. Remove oil pump while pushing in on input shaft. See Fig 25.
    Fig 25: Removing Oil Pump While Pushing In On Input Shaft

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - BELLHOUSING

    2 - OIL PUMP GASKET

    CAUTION: By-pass valve must be replaced if transmission failure occurs.
25. Remove the cooler by-pass valve. See Fig 27.
    Fig 27: Identifying Cooler By-Pass Valve

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - BYPASS VALVE

26. Remove the #1 caged needle bearing. See Fig 28.
    Fig 28: Removing/Installing No. 1 Caged Needle Bearing

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - #1 CAGED NEEDLE BEARING

    2 - NOTE: TANGED SIDE OUT

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - INPUT CLUTCH ASSEMBLY

28. Remove the #4 thrust plate. See Fig 30.
    Fig 30: Remove #4 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #4 THRUST PLATE (SELECT)

    3 - PETROLATUM FOR RETENTION

29. Remove the front sun gear assembly and #4 thrust washer (if still in place). See Fig 31.
    Fig 31: View Of Front Sun Gear Assembly And #4 Thrust Washer

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - FRONT SUN GEAR ASSEMBLY

    2 - #4 THRUST WASHER (FOUR TABS)

30. Remove the front carrier/rear annulus and #6 needle bearing. See Fig 32.
    Fig 32: Identifying Front Carrier/Rear Annulus And Needle Bearing

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - #6 NEEDLE BEARING

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

31. Remove the rear sun gear and #7 needle bearing. See Fig 33 and Fig 34.
    Fig 33: View Of Rear Sun Gear And Needle Bearing

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - #7 NEEDLE BEARING

    2 - REAR SUN GEAR

    NOTE: The number seven needle bearing has three anti-reversal 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. See Fig 34.
    Fig 34: Identifying Rear Sun Gear & No. 7 Needle Bearing

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - #7 BEARING

    2 - REAR SUN GEAR

    NOTE: Verify that Compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the Compressor 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
32. Install and load Compressor 5058A to remove the 2/4 clutch retainer snap ring. See Fig 35.
    Fig 35: Removing/Installing 2/4 Clutch Retainer Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - TOOL 5058

    2 - SCREWDRIVER

    3 - SNAP RING

    4 - 2/4 CLUTCH RETAINER

    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
33. Remove the 2/4 clutch retainer. See Fig 36 and Fig 37.
    Fig 36: Installing 2/4 Clutch Retainer

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - 2/4 CLUTCH RETAINER

    Fig 37: View Of 2/4 Clutch Retainer & Return Spring

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - 2/4 CLUTCH RETAINER

    2 - 2/4 CLUTCH RETURN SPRING

34. Remove the 2/4 clutch return spring. See Fig 38.
    Fig 38: Removing/Installing 2/4 Clutch Return Spring

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - 2/4 CLUTCH RETURN SPRING

35. Remove the 2/4 clutch pack. See Fig 39.
    Fig 39: Removing/Installing 2/4 Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - CLUTCH PLATE (4)

    2 - CLUTCH DISC (4)

36. Remove the tapered snap ring. See Fig 40.
    Fig 40: Removing Tapered Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - LOW/REVERSE CLUTCH REACTION PLATE

    2 - LONG TAB

    3 - SCREWDRIVER

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

    5 - OIL PAN FACE

37. Remove the low/reverse reaction plate. See Fig 41.
    Fig 41: Removing/Installing Low/Reverse Reaction Plate

    Courtesy of DAIMLERCHRYSLER CORP.

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

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - ONE DISC FROM LOW/REVERSE CLUTCH

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - SCREWDRIVER

    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

    3 - DO NOT SCRATCH CLUTCH PLATE

40. Remove the low/reverse clutch pack. See Fig 44.
    Fig 44: Removing/Installing Low/Reverse Clutch Pack

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - CLUTCH PLATES (5)

    2 - CLUTCH DISCS (5)

    CAUTION: Failure to grind and open stakes of the output shaft nut will result in thread damage to the shaft during nut removal.
    WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.
41. Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in Fig 45 and Fig 46. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
    Fig 45: Locating Stakes Of Output Shaft Nut

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - OUTPUT SHAFT

    2 - GRIND HERE

    3 - GRIND HERE

    4 - NUT STAKE

    Fig 46: View Of Stake Grinding Pattern

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - OUTPUT SHAFT

    2 - OUTPUT SHAFT NUT

42. Using a small chisel, carefully open the stakes on nut. See Fig 47.
    Fig 47: Opening Nut Stakes

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - CHISEL

    2 - NUT STAKE

43. Use Wrench 6497 and Wrench 6498A to remove the transfer shaft nut or the output shaft nut. See Fig 48.
    Fig 48: Removing/Installing Output Shaft Nut

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - WRENCH 6497

    2 - WRENCH 6498A

    3 - BREAKER BAR

44. Remove the output shaft from case using a press. See Fig 49.
    Fig 49: Removing Output Shaft From Case Using Shop Press

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - OUTPUT SHAFT

    2 - PRESS

    3 - TRANSMISSION CASE

    Use Remover 6596 with a press to remove the front output shaft bearing cup. See Fig 50.

    Fig 50: Removing Front Bearing Cup

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - PRESS

    2 - REMOVER 6596

45. Use Remover 6597 and Universal Handle C-4171 and Handle Extension C-4171-2 to press the rear output shaft bearing cup rearward. See Fig 51.
    Fig 51: Removing Rear Output Shaft Bearing Cup

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - UNIVERSAL HANDLE 4171 AND HANDLE EXTENSION 4171-2

    2 - REMOVER 6597

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - INSTALLER 5048-1

    2 - PULLER JAWS 6545

    3 - REAR CARRIER

    4 - INSTALLER 5048

47. Install and load compressor as shown in Fig 53 and Fig 54.
    Fig 53: Low/Reverse Spring Compressor Tool

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - DISC 6057

    2 - COMPRESSOR 5059

    3 - COMPRESSOR 5058-3

    Fig 54: Compressor Tool In Use

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - LOW/REVERSE CLUTCH RETURN SPRING

    2 - SNAP RING (INSTALL AS SHOWN)

    3 - COMPRESSOR 5058A-3

    4 - COMPRESSOR 5059A

    5 - DISC 6057

48. Remove the low/reverse Belleville spring snap ring. See Fig 55.
    Fig 55: Removing Belleville Spring Snap Ring

    Courtesy of DAIMLERCHRYSLER CORP.

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

    2 - SNAP RING PLIERS

    3 - COMPRESSOR 5059A

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - LOW/REVERSE PISTON RETURN SPRING

    2 - PISTON

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

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - PIN PUNCH

    2 - GUIDE BRACKET ASSEMBLY

52. Remove the guide bracket pivot shaft. See Fig 58. Inspect all components for wear and replace if necessary. See Fig 59.
    Fig 58: Removing/Installing Guide Bracket Pivot Pin

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - PIVOT PIN

    2 - GUIDE BRACKET ASSEMBLY

    Fig 59: Guide Bracket Assembly

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - GUIDE BRACKET

    2 - PAWL

    3 - SPLIT SLEEVE

    4 - SPACER

    5 - STEPPED SPACER

    6 - ANTI-RATCHET SPRING

    NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
53. Remove the low/reverse clutch piston. See Fig 60.
    Fig 60: Removing/Installing Low/Reverse Clutch Piston

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - LOW/REVERSE CLUTCH PISTON

    2 - BONDED SEAL

    3 - BONDED SEAL

54. Remove the low/reverse piston retainer screws.
55. Remove low/reverse piston retainer. See Fig 61.
    Fig 61: Removing/Installing Piston Retainer

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - LOW/REVERSE CLUTCH PISTON RETAINER

    2 - GASKET

56. Remove the low/reverse piston retainer gasket. See Fig 62.

Fig 62: Removing/Installing Piston Retainer Gasket

Courtesy of DAIMLERCHRYSLER CORP.