Section 2 (42RLE Automatic Transmission (Service Information)): Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

NOTE:

If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using a Scan Tool. Refer to MODULE, TRANSMISSION CONTROL, STANDARD PROCEDURE .

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

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.

Fig 1: Identifying Torque Converter

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1 - TORQUE CONVERTER

2 - TRANSMISSION

3 - INPUT SHAFT

Remove the torque converter from the transmission input shaft.

Fig 2: Measuring Input Shaft End Play

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339A

Measure input shaft end play using End Play Set (special tool #8266B, End Play Socket Set). Set up the required pieces from End Play Set (special tool #8266B, End Play Socket Set) and a dial indicator as shown in illustration. 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 3: Remove Adapter Housing Bolts

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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

3 - BOLTS

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.

Remove the bolts that hold the adapter housing onto the transmission case.

Fig 4: Remove Adapter Housing
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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

NOTE:
There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case

Remove the adapter housing from the transmission case.

Fig 5: Identifying Housing, Lube Tube, Grommet & Pry Slots

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1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

Inspect the lube tube grommet for damage. If the grommet lip is damaged, it will need to be replaced.

Fig 6: Removing 4x4 Stub Shaft
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Using OTC® Slide Hammer 1155 or 7703 (3), or equivalent, and Adapter (special tool #10171, Adapter, Stub Shaft Remover) (2), 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.

Fig 7: Identifying Input Speed Sensor Bolt
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1 - INPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the input speed sensor bolt and sensor.

Fig 8: Identifying Output Speed Sensor Bolt
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the output speed sensor bolt and sensor.

Fig 9: Identifying 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.

Fig 10: Identifying Transmission Oil Pan
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1 - TRANSMISSION OIL PAN
Remove the transmission oil pan.

Fig 11: Identifying Oil Filter Screws
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1 - OIL FILTER

2 - SCREWS
Remove the transmission oil filter screws.

Fig 12: Identifying Transmission Filter
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1 - TRANSMISSION FILTER
Remove transmission oil filter.

Fig 13: Locating Oil Filter O-ring
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1 - VALVE BODY

2 - O-RING
Remove the oil filter o-ring from the valve body.

Fig 14: Identifying Valve Body Bolts
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1 - BOLTS
Remove valve body-to-case bolts.

Fig 15: Identifying 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 from transmission.

Fig 16: Identifying Underdrive And Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Remove underdrive and overdrive accumulators.

Fig 17: Remove Low/Reverse Accumulator
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Remove the low/reverse accumulator snap ring.

Fig 18: Installing Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Remove the low/reverse accumulator plug.

Fig 19: Low/Reverse Accumulator Piston & Springs
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1 - PISTON

2 - RETURN SPRINGS
Remove low/reverse accumulator piston and springs.

Fig 20: Identifying Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP

NOTE:
The oil pump bolts are not to be reused.
Remove and discard the oil pump-to-case bolts.

Fig 21: Oil Pump Pullers
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1 - OIL PUMP

2 - PULLERS
Remove oil pump using Slide Hammers (special tool #C-3752, Slide Hammers).

Fig 22: Removing Oil Pump While Pushing In On Input Shaft
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
Remove oil pump while pushing in on input shaft.

Fig 23: Identifying Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Remove oil pump gasket.

Fig 24: Identifying 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.

Fig 25: Installing Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove the #1 caged needle bearing.

Fig 26: Installing Input Clutch Assembly With Proper Thrust Plate
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1 - INPUT CLUTCH ASSEMBLY

Remove the input clutch assembly.

Fig 27: Removing/Installing Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Remove the #4 thrust plate.

Fig 28: Removing/Installing Front Sun Gear Assembly And #4 Thrust Washer
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

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

Fig 29: Remove 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 and #6 needle bearing.

Fig 30: Removing/Installing Rear Sun Gear
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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.

Remove the rear sun gear and #7 needle bearing and.

Fig 31: Identifying 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058A

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE:

Verify that Compressor (special tool #5058A, Compressor, Spring) is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the Compressor (special tool #5058A, Compressor, Spring) bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Install and load Compressor (special tool #5058A, Compressor, Spring) 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 32: Removing 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

2 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch retainer.

Fig 33: Installing 2/4 Clutch Belleville Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch return spring.

Fig 34: Installing 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

Remove the 2/4 clutch pack.

Fig 35: Removing 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.

Fig 36: Installing Low/Reverse Reaction Plate With Flat Side Up
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove the low/reverse reaction plate.

Fig 37: Installing One Low/Reverse Clutch Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

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

Fig 38: 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.

Fig 39: Installing Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Remove the low/reverse clutch pack.

Fig 40: Grinding To Open Staking On Output Shaft Nut

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1 - OUTPUT SHAFT

2 - GRIND HERE

3 - GRIND HERE

4 - NUT STAKE

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.

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in illustration. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Fig 41: Opening Stakes On Nut
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1 - CHISEL

2 - NUT STAKE

Using a small chisel, carefully open the stakes on nut.

Fig 42: Identifying Output Shaft Nut

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1 - WRENCH 6497

2 - WRENCH 6498A

3 - BREAKER BAR

Use Wrench (special tool #6497, Wrench, Transfer Shaft) and Wrench (special tool #6498A, Wrench, Socket) to remove the transfer shaft nut or the output shaft nut.

Fig 43: Removing Output Shaft From Case Using Shop Press

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1 - OUTPUT SHAFT

2 - PRESS

3 - TRANSMISSION CASE

Remove the output shaft from case using a press.

Fig 44: Removing Front Output Shaft Bearing Cup
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1 - PRESS

2 - REMOVER 6596

Use Remover (special tool #6596, Remover, Bearing Cup) with a press to remove the front output shaft bearing cup.

Fig 45: Pressing Rear Output Shaft Bearing Cup
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1 - UNIVERSAL HANDLE 4171 AND HANDLE EXTENSION 4171-2

2 - REMOVER 6597

Use Remover (special tool #6597, Remover, Bearing Cup) and Universal Handle (special tool #C-4171, Driver Handle, Universal) and Handle Extension (special tool #C-4171-2, Extension, Drive Handle) to press the rear output shaft bearing cup rearward.

Fig 46: Removing Rear Carrier Front Bearing Cone

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1 - INSTALLER 5048-1

2 - PULLER JAWS 6545

3 - REAR CARRIER

4 - INSTALLER 5048

Remove the rear carrier front bearing cone.

Fig 47: Low/Reverse Spring Compressor Tool

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1 - DISC 6057

2 - COMPRESSOR 5059-A

3 - COMPRESSOR 5058-3

Fig 48: Installing And Load Compressor

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN in illustration)

3 - COMPRESSOR 5058A-3

4 - COMPRESSOR 5059-A

5 - DISC 6057

Install and load compressor

Fig 49: Removing Low/Reverse Belleville Spring Snap Ring

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

2 - SNAP RING PLIERS

3 - COMPRESSOR 5059-A

Remove the low/reverse belleville spring snap ring.

Fig 50: Installing Low/Reverse Piston Belleville Spring Into Position
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON
Remove the low/reverse piston belleville spring.
Remove the park sprag pivot retaining screw.

Fig 51: Anchor Shaft Removal
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1 - PIN PUNCH

2 - GUIDE BRACKET ASSEMBLY

Drive out the anchor shaft using suitable punch.

Fig 52: Installing Guide Bracket Pivot Pin

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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

Fig 53: Guide Bracket Disassembled

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1 - GUIDE BRACKET

2 - PAWL

3 - SPLIT SLEEVE

4 - SPACER

5 - STEPPED SPACER

6 - ANTIRATCHET SPRING

Remove the guide bracket pivot shaft. Inspect all components for wear and replace if necessary.

Fig 54: Identifying Low/Reverse Clutch Piston

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1 - LOW/REVERSE CLUTCH PISTON

2 - BONDED SEAL

3 - BONDED 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.
Remove the low/reverse piston retainer screws.

Fig 55: Identifying Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer.

Fig 56: Installing Low/Reverse 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.