42RLE Automatic Transmission (Service Information): Disassembly

NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) .

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.

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

Fig 1: Remove Torque Converter

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1 - TORQUE CONVERTER

2 - TRANSMISSION

3 - INPUT SHAFT

Remove the torque converter (1) from the transmission input shaft (3). See Fig 1.

Fig 2: Measure Input Shaft End Play Using Tool 8266 - Typical

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

Measure input shaft end play using Tool 8266 (1, 2). Set up Tool 8266 and a dial indicator as shown. See Fig 2.
Move input shaft in and out to obtain end play reading. End play specifications are 0.13 to 0.64 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 Rear Output Shaft Retaining Ring
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1 - RETAINING RING

2 - OUTPUT SHAFT BEARING

NOTE: It is not necessary to remove the output shaft flange to disassemble the transmission. Perform the following steps only if it necessary to replace a component in the extension housing assembly.
Place the transmission in PARK to prepare for the removal of the output shaft nut.
Remove the nut holding the propeller shaft flange to the output shaft and remove the flange.
Remove the transmission rear oil seal with a suitable slide hammer and screw.
Remove the transmission output shaft washer.

Remove the transmission rear output shaft bearing retaining ring (1). See Fig 3.

Fig 4: Position Remover 9082 On Bearing

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1 - BEARING REMOVER 9082

2 - TRANSMISSION CASE

3 - OUTPUT SHAFT BEARING

Position Bearing Remover 9082 (1) over the inner race of the output shaft bearing (3). See Fig 4.

Fig 5: Slide Remover 9082 Collar Downward

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1 - BEARING REMOVER 9082

2 - TRANSMISSION CASE

3 - COLLAR

4 - FINGERS

Slide the collar (3) on the Bearing Remover 9082 (1) downward over the fingers (4) of the tool. See Fig 5.

Fig 6: Remove Output Shaft Bearing

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1 - BEARING REMOVER 9082

2 - TRANSMISSION CASE

3 - OUTPUT SHAFT BEARING

Remove the output shaft bearing (3). See Fig 6.
Remove the geartrain end-play shim from the output shaft. Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged.

Fig 7: Remove Adapter/Extension Housing Bolts
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NOTE: The four bolts (3) along the bottom of the extension housing (2) 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 extension housing (2) onto the transmission case. See Fig 7.

Fig 8: Remove Extension Housing
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Remove the extension (2) housing from the transmission case. See Fig 8. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.

Fig 9: Lube Tube Grommet

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1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

Inspect the lube tube grommet (3) for damage. See Fig 9. If the grommet lip is damaged, it will need to be replaced.

Fig 10: Remove Input Speed Sensor Bolt
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1 - INPUT SPEED SENSOR

2 - TRANSMISSION CASE

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
Remove the input speed sensor bolt. See Fig 10.

Fig 11: Remove Output Speed Sensor Bolt
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
Remove the output speed sensor bolt. See Fig 11.

Fig 12: Remove Output Speed Sensor
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the input and output (2) speed sensors. See Fig 12. Identify the speed sensors for re-installation since they are not interchangeable.

Fig 13: Remove 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 (2). See Fig 13.

Fig 14: Remove Transmission Oil Pan
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1 - TRANSMISSION OIL PAN
Remove the transmission oil pan (1). See Fig 14.

Fig 15: Remove Oil Filter Screws
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1 - OIL FILTER

2 - SCREWS
Remove the transmission oil filter screws (2). See Fig 15.

Fig 16: Remove Transmission Filter
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1 - TRANSMISSION FILTER
Remove transmission oil filter (1). See Fig 16.

Fig 17: Remove Oil Filter O-Ring
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1 - VALVE BODY

2 - O-RING
Remove the oil filter o-ring (2) from the valve body. See Fig 17.
If necessary, use a suitable tool to push the transmission fill tube grommet and extension from the transmission case from the bottom.

Fig 18: Remove Valve Body Bolts
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1 - BOLTS
Remove valve body-to-case bolts (1). See Fig 18.

Fig 19: Remove Valve Body From Transmission
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1 - VALVE BODY

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Remove valve body (1) from transmission. See Fig 19.

Fig 20: Underdrive and Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Remove underdrive and overdrive accumulators (1, 2). See Fig 20.

Fig 21: Remove Low/Reverse Accumulator
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Remove the low/reverse accumulator snap ring (1). See Fig 21.

Fig 22: Remove Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Remove the low/reverse accumulator plug (2). See Fig 22.

Fig 23: Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON
Remove low/reverse accumulator piston (1) using suitable pliers. See Fig 23.

Fig 24: Low/Reverse Accumulator
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1 - PISTON

2 - RETURN SPRINGS
Remove piston (1) and springs (2). See Fig 24.

Fig 25: Remove Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP
Remove and discard the oil pump-to-case bolts (1). See Fig 25. The oil pump bolts are not to be reused.

Fig 26: Oil Pump Pullers
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1 - OIL PUMP

2 - PULLERS
Remove oil pump using C-3752 Pullers (2). See Fig 26.

Fig 27: Remove Oil Pump
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
Remove oil pump while pushing in on input shaft (1). See Fig 27.

Fig 28: Remove Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Remove oil pump gasket (2). See Fig 28.

Fig 29: Remove 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 (1). See Fig 29.

Fig 30: Remove No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove the #1 caged needle bearing (1). See Fig 30.

Fig 31: Remove Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY

Remove the input clutch assembly (1). See Fig 31.

Fig 32: Remove #4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Remove the #4 thrust plate (2). See Fig 32.

Fig 33: Remove Front Sun Gear Assembly
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Remove the front sun gear assembly (1) and #4 thrust washer (if still in place). See Fig 33.

Fig 34: 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 (2) and #6 needle bearing (1). See Fig 34.

Fig 35: Remove Rear Sun Gear
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Remove the rear sun gear (2) and #7 needle bearing (1). See Fig 35.

Fig 36: Number 7 Bearing

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1 - #7 BEARING

2 - REAR SUN GEAR

NOTE: The number seven needle bearing (1) has three antireversal tabs and is common with the number five and number two position. See Fig 36. 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 37: Remove 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE: Verify that Tool 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.

Install and load Tool 5058A to remove the 2/4 clutch retainer snap ring (3). See Fig 37.

Fig 38: 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

2 - 2/4 CLUTCH RETURN SPRING

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Remove the 2/4 clutch retainer (1). See Fig 38.

Fig 39: Remove 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch return spring (1). See Fig 39.

Fig 40: Remove 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

Remove the 2/4 clutch pack (1, 2). See Fig 40.

Fig 41: Remove 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 (4). See Fig 41.

Fig 42: Remove Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove the low/reverse reaction plate (1). See Fig 42.

Fig 43: Remove One Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove one (1) low/reverse clutch disc to facilitate snap ring removal. See Fig 43.

Fig 44: Remove 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 (2). See Fig 44.

Fig 45: Remove Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Remove the low/reverse clutch pack (1, 2). See Fig 45.

Fig 46: Grinding Stakes

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1 - OUTPUT SHAFT

2 - GRIND HERE

3 - GRIND HERE

4 - NUT STAKE

CAUTION: Failure to grind and open stakes (4) of the output shaft nut will result in thread damage to the shaft during nut removal. See Fig 46.

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.

Fig 47: Stake Grinding Pattern

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1 - OUTPUT SHAFT

2 - OUTPUT SHAFT NUT

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut (2) as shown. See Fig 47. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Fig 48: Opening Nut Stakes
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1 - CHISEL

2 - NUT STAKE

Using a small chisel (1), carefully open the stakes on nut (2). See Fig 48.

Fig 49: Remove Output Shaft Nut

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1 - SPECIAL TOOL 6497

2 - SPECIAL TOOL 6498A

3 - BREAKER BAR

Use special tool 6497 (1) and 6498A (2) to remove the output shaft nut. See Fig 49.

Fig 50: Use Arbor Press to Remove Output Shaft from Case

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1 - OUTPUT SHAFT

2 - ARBOR PRESS

3 - TRANSMISSION CASE

Remove the output shaft (1) from case (3) using a shop press (2). See Fig 50.

Fig 51: Remove Front Bearing Cup - Typical
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1 - ARBOR PRESS

2 - SPECIAL TOOL 6596
Use special tool 6596 (2) with a shop press (1) to remove the front output shaft bearing cup. See Fig 51.

Fig 52: Remove Rear Bearing Cup
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1 - SPECIAL TOOL 4171 AND 4171-2

2 - SPECIAL TOOL 6597

Use special tool 6597 (2) and handle C-4171 (1) and C-4171-2 to press the rear output shaft bearing cup rearward. See Fig 52.

Fig 53: Remove Rear Carrier Front Bearing Cone

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1 - SPECIAL TOOL 5048-1

2 - SPECIAL TOOL 6545

3 - REAR CARRIER

4 - SPECIAL TOOL 5048

Remove the rear carrier front bearing cone (3). See Fig 53.

Fig 54: Compressor Tool in Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - TOOL 5058A-3

4 - TOOL 5059A

5 - SPECIAL TOOL 6057

Install and load compressor 5059A (4) as shown. See Fig 54.

Fig 55: Remove Snap Ring

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

2 - SNAP RING PLIERS

3 - SPECIAL TOOL 5059A

Remove the low/reverse belleville spring snap ring (1). See Fig 55.

Fig 56: Low/Reverse Piston Belleville Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON
Remove the low/reverse piston belleville spring (1). See Fig 56.

Fig 57: Anchor Shaft Removal
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1 - PIN PUNCH

2 - GUIDE BRACKET ASSEMBLY
Remove the park sprag pivot retaining screw.
Drive out the anchor shaft using suitable punch (1). See Fig 57.

Fig 58: Remove Guide Bracket Pivot Shaft
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

Remove the guide bracket pivot pin (1). See Fig 58. Inspect all components for wear and replace if necessary.

Fig 59: Remove Low/Reverse Clutch Piston

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1 - LOW/REVERSE CLUTCH PISTON

2 - D-RING SEAL

3 - D-RING 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 (1). See Fig 59.
Remove the low/reverse piston retainer screws.

Fig 60: Remove Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer (1). See Fig 60.

Fig 61: Remove 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 (2). See Fig 61.