42RLE - Service Information: Disassembly

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

Fig 1: Identifying Torque Converter And Transmission Input Shaft

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1. Remove the torque converter (1) from the transmission input shaft (3). 
   Fig 2: Measuring Input Shaft End Play

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2. Measure input shaft end play using pieces from End Play Set 8266 (1, 2). Set up tool 8266 and Dial Indicator C-3339 as shown in  Fig 2 . 
3. 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: Identifying Transmission Case, Bolts And Adapter Housing

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   NOTE: The four bolts (3) along the bottom of the adapter or extension housing (2) have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.
4. Remove the bolts that hold the adapter or extension housing (2) onto the transmission case. 
   Fig 4: Identifying Transmission Case And Adapter Housing

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5. Remove the adapter (2) housing, 4X4 vehicles only, 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. 
   Fig 5: Identifying Transmission Case And Extension Housing

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6. Remove the extension (2) housing, 4X2 vehicles only, 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. 
   Fig 6: Identifying Pry Slots, Lube Tube, Grommet And Housing

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7. Inspect the lube tube grommet (3) for damage. If the grommet lip is damaged, it will need to be replaced. 
8. On 4X2 transmissions, perform the following, if necessary: 
   Fig 7: Identifying Extension Shaft, Bearing & Snap Ring

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   (1) Remove the extension shaft bearing snap ring (3) from the extension housing. 

   Fig 8: Identifying Extension Shaft And Bearing Assembly

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   (2) Remove the extension shaft and bearing assembly (2) from the extension housing (1). 

   Fig 9: Identifying Extension Shaft Bearing And Retaining Ring

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   (3) Remove the extension shaft bearing retaining ring (3) from the extension shaft (1). 

   Fig 10: Identifying Extension Shaft Bearing

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   (4) Remove the extension shaft bearing (2) from the extension shaft (1). 

   Fig 11: Identifying 4X4 Stub Shaft

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9. Using a Slide Hammer C-3752 (2), remove the 4X4 stub shaft (1). 
   Fig 12: Identifying Stub Shaft And Transmission Output Shaft

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10. Remove the 4X4 stub shaft (1) from the transmission output shaft. Inspect the circlip on the shaft for damage and replace the clip if necessary. 
    Fig 13: Identifying Transmission Case And Input Speed Sensor

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    NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
11. Remove the input speed sensor bolt. 
    Fig 14: Identifying Transmission Case And Output Speed Sensor

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    NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
12. Remove the output speed sensor bolt. 
    Fig 15: Identifying Transmission Case And Output Speed Sensor

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13. Remove the input and output (2) speed sensors. Identify the speed sensors for re-installation since they are not interchangeable. 
    Fig 16: Identifying Transmission Oil Pan Bolts

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    NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.
14. Remove the transmission oil pan bolts (2). 
    Fig 17: Identifying Transmission Oil Pan

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15. Remove the transmission oil pan (1). 
    Fig 18: Identifying Transmission Oil Filter Screws

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16. Remove the transmission oil filter screws (2). 
    Fig 19: Identifying Transmission Oil Filter

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17. Remove transmission oil filter (1). 
    Fig 20: Identifying Oil Filter O-Ring & Valve Body

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18. Remove the oil filter O-ring (2) from the valve body. 
    Fig 21: Identifying Valve Body-To-Case Bolts

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19. Remove valve body-to-case bolts (1). 
    Fig 22: Identifying Transmission Valve Body

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    CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
20. Remove valve body (1) from transmission. 
    Fig 23: Identifying Underdrive And Overdrive Accumulators

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21. Remove underdrive and overdrive accumulators (1, 2). 
    Fig 24: Identifying Low/Reverse Accumulator And Snap Ring

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22. Remove the low/reverse accumulator snap ring (1). 
    Fig 25: Identifying Low/Reverse Accumulator Plug

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23. Remove the low/reverse accumulator plug (2). 
    Fig 26: Identifying Low/Reverse Accumulator Piston

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24. Remove low/reverse accumulator piston (1) using suitable pliers. 
    Fig 27: Identifying Piston And Springs

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25. Remove piston (1) and springs (2). 
    Fig 28: Identifying Oil Pump-To-Case Bolts

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26. Remove and discard the oil pump-to-case bolts (1). The oil pump bolts are not to be reused. 
    Fig 29: Identifying Oil Pump And Pullers

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27. Remove oil pump using Slide Hammers C-3752 (2). 
    Fig 30: Removing Oil Pump Pushing On Input Shaft

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28. Remove oil pump while pushing in on input shaft (1). 
    Fig 31: Identifying Oil Pump Gasket

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29. Remove oil pump gasket (2). 
    Fig 32: Identifying Cooler By-Pass Valve

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    CAUTION: By-pass valve must be replaced if transmission failure occurs.
30. Remove the cooler by-pass valve (1). 
    Fig 33: Identifying Caged Needle Bearing

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31. Remove the #1 caged needle bearing (1). 
    Fig 34: Identifying Input Clutch Assembly

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32. Remove the input clutch assembly (1). 
    Fig 35: Identifying Thrust Plate

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33. Remove the #4 thrust plate (2). 
    Fig 36: Identifying Front Sun Gear Assembly And Thrust Washer

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34. Remove the front sun gear assembly (1) and #4 thrust washer (if still in place). 
    Fig 37: Identifying Front Carrier/Rear Annulus And Needle Bearing

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35. Remove the front carrier/rear annulus (2) and #6 needle bearing (1). 
    Fig 38: Identifying Needle Bearing & Rear Sun Gear

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36. Remove the rear sun gear (2) and #7 needle bearing (1). 
    Fig 39: Identifying Rear Sun Gear And Bearing

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    NOTE: The number seven needle bearing (1) 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
    Fig 40: 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.
37. Install and load Compressor 5058A to remove the 2/4 clutch retainer snap ring (3). 
    Fig 41: Identifying 2/4 Clutch Retainer

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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.
38. Remove the 2/4 clutch retainer (1). 
    Fig 42: Identifying 2/4 Clutch Return Spring

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39. Remove the 2/4 clutch return spring (1). 
    Fig 43: Removing/Installing 2/4 Clutch Pack

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40. Remove the 2/4 clutch pack (1, 2). 
    Fig 44: Identifying Tapered Snap Ring

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41. Remove the tapered snap ring (4). 
    Fig 45: Identifying Low/Reverse Reaction Plate

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42. Remove the low/reverse reaction plate (1). 
    Fig 46: Identifying Low/Reverse Clutch Disc

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43. Remove one (1) low/reverse clutch disc to facilitate snap ring removal. 
    Fig 47: Identifying Low/Reverse Reaction Plate Snap Ring

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44. Remove the low/reverse reaction plate snap ring (2). 
    Fig 48: Identifying Low/Reverse Clutch Pack

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45. Remove the low/reverse clutch pack (1, 2). 
    Fig 49: Identifying Output Shaft Nut Stake Location

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    CAUTION: Failure to grind and open stakes (4) of the output shaft nut will result in thread damage to the shaft during nut removal.
    WARNING: Wear safety goggles while grinding stake nuts.
    Fig 50: Identifying Output Shaft Nut

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46. Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut (2) as shown in  Fig 49 . Do not grind all the way through the nut and into the shaft. There are two stakes on each nut. 
    Fig 51: Identifying Small Chisel And Stakes On Nut

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47. Using a small chisel (1), carefully open the stakes on nut (2). 
    Fig 52: Removing Output Shaft Nut

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48. Use Wrench 6497 (1) and Wrench 6498A (2) to remove the output shaft nut. 
    Fig 53: Identifying Output Shaft At Transmission Case

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49. Remove the output shaft (1) from case (3) using a shop press (2). 
    Fig 54: Identifying Arbor Press & Cup Remover

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50. Use Remover 6596 (2) with a shop press (1) to remove the front output shaft bearing cup. 
    Fig 55: Removing Rear Output Shaft Bearing Cup Using Special Tool

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51. Use Remover 6597 (2) and Universal Handle C-4171 (1) and Handle Extension C-4171-2 to press the rear output shaft bearing cup rearward. 
    Fig 56: Removing Rear Carrier Front Bearing Cone

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52. Remove the rear carrier front bearing cone (3). 
    Fig 57: Identifying Low/Reverse Clutch Return Spring And Compressor (5059A)

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53. Install and load compressor 5059A (4) as shown in  Fig 57 . 
    Fig 58: Identifying Low/Reverse Belleville Spring Snap Ring

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54. Remove the low/reverse Belleville spring snap ring (1). 
    Fig 59: Identifying Low/Reverse Piston Belleville Spring

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55. Remove the low/reverse piston Belleville spring (1). 
    Fig 60: Identifying Pin Punch And Guide Bracket Assembly

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56. Remove the park sprag pivot retaining screw. 
57. Drive out the anchor shaft using suitable punch (1). 
    Fig 61: Identifying Guide Bracket Pivot Pin

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58. Remove the guide bracket pivot pin (1). Inspect all components for wear and replace if necessary. 
    Fig 62: 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.
59. Remove the low/reverse clutch piston (1). 
60. Remove the low/reverse piston retainer screws. 
    Fig 63: Identifying Low/Reverse Piston Retainer

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61. Remove low/reverse piston retainer (1). 
    Fig 64: Identifying Low/Reverse Piston Retainer Gasket

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62. Remove the low/reverse piston retainer gasket (2).