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 scan tool. Refer to STANDARD PROCEDURE .

Fig 1: Installing Output Bearing Cups Using Installer

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Install the output bearing cups using Installer - 5050A.

Fig 2: Identifying Low/Reverse Piston Retainer Gasket
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Install low/reverse piston retainer gasket (2).

Fig 3: Identifying Low/Reverse Piston Retainer
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Install low/reverse piston retainer (1).

Fig 4: Identifying Low/Reverse Piston Retainer-To-Case Screws
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Install low/reverse piston retainer-to-case screws (3) and torque to 5 N.m (45 in. lbs.).

Fig 5: Identifying Low/Reverse Clutch Piston
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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.
Install low/reverse clutch piston (1).

Fig 6: Installing Guide Bracket Assembly
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Assemble guide bracket (1) assembly as shown, if necessary. See Fig 6 .

Fig 7: Installing Guide Bracket Pivot Pin
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CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case.
Install guide bracket pivot pin (1).
Install park sprag pivot retaining bolt and torque to 4.5 N.m (40 in. lbs.).

Fig 8: Installing Low/Reverse Piston Belleville Spring
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Install low/reverse piston Belleville spring (1) into position.

Fig 9: Identifying Low/Reverse Clutch Return Spring And Snap Ring
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Install and load low/reverse spring compressor tools (Compressors 5058A-3 and 5059A and Disk 6057) (3, 4, 5) as shown in Fig 9 to facilitate snap ring (2) installation.

Fig 10: Installing Snap Ring
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Install snap ring (1) and remove the tools.

Fig 11: Identifying Rear Carrier
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Install rear carrier (4) front bearing cone.

Fig 12: Installing Rear Output Shaft Bearing Cone And Support Plate (6618A)
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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
PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and Support Plate 6618A (1).

Fig 13: Identifying Support Plate (6618A)
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Install Support Plate 6618A (1). 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 Support Plate 6618A. Ensure your press table has clearance for the output shaft.

Fig 14: Identifying Shim On Output Shaft
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Install shim (1) on output shaft (2). 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 15: Pressing Output Shaft/Rear Carrier Into Rear Bearing
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Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use Disc MD-998911 (2), Universal Handle C-4171 and Handle Extension C-4171-2 (Handle) (1) to press shaft into rear bearing.

Fig 16: Identifying Output Shaft Nut
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CAUTION: Do not reuse old output shaft nut because the removed stake weakens the nut flange. Using Wrenches 6497 and 6498-A, install new output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.).
Check the turning torque (1) 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 17: Identifying Nut And Staking Tool (6639)
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CAUTION: Failure to stake nut could allow the nut to back- off during use.
The new nut (3) must be staked after the correct turning torque is obtained. Use Staking Tool 6639 (2) to stake output shaft nut.

Fig 18: Identifying Slot And Staked Nut
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Verify that the nut has been properly staked to the output shaft.

Fig 19: Installing Low/Reverse Clutch Pack
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Install low/reverse clutch pack (1, 2). Leave uppermost disc out to facilitate snap ring installation.

Fig 20: Identifying Low/Reverse Reaction Plate Snap Ring
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Install low/reverse reaction plate snap ring (2).

Fig 21: Identifying Low/Reverse Clutch Disc
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Install one low/reverse clutch disc (1).

Fig 22: Identifying Low/Reverse Reaction Plate
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Install low/reverse reaction plate (1) with flat side up.

Fig 23: Installing Tapered Snap Ring
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Install a new tapered snap ring (2) (tapered side out).

Fig 24: Ensuring Snap Ring Ends Are Oriented Correctly
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Make sure that the snap ring ends are oriented as shown in Fig 24 .

Fig 25: Measuring Low/Reverse Clutch Pack Clearance
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Measure low/reverse clutch pack. Set up Dial Indicator C-3339 (1) as shown in Fig 25 . 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).
Select the proper low/reverse reaction plate to achieve specifications.

Fig 26: Removing/Installing 2/4 Clutch Pack
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Install 2/4 clutch pack (1, 2).

Fig 27: Identifying 2/4 Clutch Return Spring
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NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Install 2/4 clutch Belleville spring (1).

Fig 28: Installing Return Spring To 2/4 Retainer
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Verify the proper orientation of the return spring (2) to the 2/4 retainer (3).

Fig 29: Installing 2/4 Clutch Retainer
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Install 2/4 clutch retainer (1).

Fig 30: Identifying 2/4 Clutch Retainer And Snap Ring
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NOTE: Verify that Compressor 5058A (1) is centered properly over the 2/4 clutch retainer (4) 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.
Set up Compressor 5058A (1) as shown in Fig 30 . Compress 2/4 clutch just enough to facilitate snap ring installation.

Fig 31: Measuring 2/4 Clutch Clearance
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Measure 2/4 clutch clearance: Set up dial indicator (1) as shown in Fig 31 . 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 32: Removing/Installing Needle Bearing At Rear Sun Gear
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Install the #7 needle bearing (1) to the rear sun gear (2). 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 33: Identifying Needle Bearing & Rear Sun Gear
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Install rear sun gear (2) and #7 needle bearing (1).

Fig 34: Identifying Front Carrier/Rear Annulus And Needle Bearing
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Install front carrier/rear annulus assembly (2) and #6 needle bearing (1).

Fig 35: Identifying Front Sun Gear Assembly And Thrust Washer
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Install front sun gear assembly (1) and #4 thrust washer (2).

Fig 36: Identifying Thrust Plate
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Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate.
Install #4 thrust plate (2) using petrolatum to hold into position.
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 clutches assembly is not seated properly.

Fig 37: Identifying Oil Pump Assembly And O-Ring
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Remove the oil pump o-ring (2) and install oil pump and gasket to transmission. 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.

Fig 38: Measuring Input Shaft End Play With Transmission In Vertical Position
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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 (1, 2) and Dial Indicator Set C-3339 (3) as shown in Fig 38 .
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.

Fig 39: Identifying Input Clutch Assembly
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Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
Install input clutch assembly (1) with proper thrust plate.

Fig 40: Identifying Caged Needle Bearing
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Install #1 caged needle bearing (1).

Fig 41: Identifying Cooler By-Pass Valve
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CAUTION: By-pass valve MUST be replaced if transmission failure occurs.
Replace cooler by-pass valve (1) if transmission failure has occurred.

Fig 42: Identifying Oil Pump Gasket
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NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.
Install oil pump gasket (2).

Fig 43: Identifying Oil Pump-To-Case Bolts
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Install oil pump (2) and torque oil pump-to-case bolts (1) to 30 N.m (265 in. lbs.). Do not reuse original oil pump bolts.

Fig 44: Identifying Low/Reverse Accumulator Plug
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Install low/reverse accumulator (1) as shown in Fig 44 .

Fig 45: Identifying Low/Reverse Accumulator Plug
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Install low/reverse accumulator plug (2).

Fig 46: Identifying Low/Reverse Accumulator And Snap Ring
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Install low/reverse accumulator snap ring (1).

Fig 47: Identifying Underdrive And Overdrive Accumulators
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Install underdrive (2) and overdrive (1) accumulators and springs.

Fig 48: Identifying Transmission Valve Body
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CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Install valve body (1) into place as shown in Fig 48 .

Fig 49: Installing Seven Valve Body-To-Case Bolts
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Install seven (7) valve body-to-case bolts (1) and torque to 12 N.m (105 in. lbs.).

Fig 50: Identifying Transmission Oil Filter
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Install transmission oil filter (1). Tighten the bolts to 5 N.m (45 in. lbs.).

Fig 51: Identifying Transmission Oil Pan
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Install transmission oil pan (1) with a bead of ATF RTV.

Fig 52: Identifying Oil Pan-To-Case Bolts & Pressure Ports
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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 Mitsubishi Lock & Seal Adhesive.
Install and torque the oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.).

Fig 53: Identifying Input And Output Speed Sensor And Transmission Range Sensor
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NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Loctite 242 Lock & Seal Adhesive or equivalent.
Install both speed sensors (1, 2) into the transmission case. Torque the speed sensor bolts to 9 (80 in. lbs.) .

Fig 54: Measuring Input Shaft End Play
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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.
On 4X2 transmissions, perform the following, if necessary:

Fig 55: Identifying Extension Shaft Bearing
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1. Install the extension shaft bearing (2) onto the extension shaft.
  
  Fig 56: Identifying Extension Shaft Bearing And Retaining Ring
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2. Install the extension shaft bearing retaining ring (3) onto the extension shaft (1).
  
  Fig 57: Identifying Extension Shaft And Bearing Assembly
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3. Install the extension shaft (2) and bearing assembly (3) into the extension housing (1).
  
  Fig 58: Identifying Extension Shaft, Bearing & Snap Ring
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4. Install the extension shaft bearing snap ring (3) into the extension housing.
  
  Fig 59: Identifying Extension Shaft Snap Ring
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5. Verify that the extension shaft snap ring (3) is fully engaged in the snap ring groove.
  
  Fig 60: Identifying Pry Slots, Lube Tube, Grommet And Housing
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Inspect the lube tube grommet (2) for damage. If the grommet lip is damaged, it will need to be replaced.

Fig 61: Identifying Transmission Case And Adapter Housing
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Install the 4X4 stub shaft onto the transmission output shaft.
Place a bead of ATF RTV on the rear surface of the transmission case for the adapter/extension housing.
Install the adapter housing (2) onto the transmission case, 4X4 vehicles only.

Fig 62: Identifying Transmission Case And Extension Housing
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Install the extension housing (2) onto the transmission case, 4X2 vehicles only.

Fig 63: Identifying Lowermost Four Adapter/Extension Housing Bolts
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NOTE: Before installing the lowermost four adapter/extension housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mitsubishi Lock & Seal Adhesive.

Fig 64: Identifying Transmission Case, Bolts And Adapter Housing
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Install the bolts that hold the adapter or extension 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.).