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 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: Removing/Installing Torque Converter

Courtesy of CHRYSLER LLC

1 - TORQUE CONVERTER

2 - TRANSMISSION

3 - INPUT SHAFT

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

Fig 2: Measuring Input Shaft End Play Using End Play Set 8266

Courtesy of CHRYSLER LLC

1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

Measure input shaft end play using End Play Set 8266 (1, 2). Set up End Play Set 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: Removing/Installing Rear Output Shaft Retaining Ring
Courtesy of CHRYSLER LLC

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: Removing Bearing

Courtesy of CHRYSLER LLC

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: Sliding Remover 9082 Collar Downward

Courtesy of CHRYSLER LLC

1 - BEARING REMOVER 9082

2 - TRANSMISSION CASE

3 - COLLAR

4 - FINGERS

NOTE: Due to production variations in the bearing, it may not be possible to slide the collar fully downward. It is only necessary to slide the collar down far enough that the fingers securely grasp the inner bearing race.

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

Fig 6: Removing Output Shaft Bearing

Courtesy of CHRYSLER LLC

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: Removing Adapter/Extension Housing Bolts
Courtesy of CHRYSLER LLC

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: Removing Extension Housing
Courtesy of CHRYSLER LLC

Remove the extension (2) 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 8.

Fig 9: Lube Tube Grommet

Courtesy of CHRYSLER LLC

1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

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

Fig 10: Removing/Installing Input Speed Sensor Bolt
Courtesy of CHRYSLER LLC

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: Removing/Installing Output Speed Sensor Bolt
Courtesy of CHRYSLER LLC

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: Removing/Installing Output Speed Sensor
Courtesy of CHRYSLER LLC

1 - OUTPUT SPEED SENSOR

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

Fig 13: Removing/Installing Transmission Oil Pan Bolts
Courtesy of CHRYSLER LLC

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: Removing/Installing Transmission Oil Pan
Courtesy of CHRYSLER LLC

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

Fig 15: Removing/Installing Oil Filter Screws
Courtesy of CHRYSLER LLC

1 - OIL FILTER

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

Fig 16: Removing/Installing Transmission Filter
Courtesy of CHRYSLER LLC

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

Fig 17: Locating Oil Filter O-Ring
Courtesy of CHRYSLER LLC

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: Removing/Installing Valve Body Bolts
Courtesy of CHRYSLER LLC

1 - BOLTS
Remove valve body-to-case bolts (1). See Fig 18.

Fig 19: Removing/Installing Valve Body
Courtesy of CHRYSLER LLC

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: Identifying Underdrive And Overdrive Accumulators
Courtesy of CHRYSLER LLC

1 - OVERDRIVE PISTON AND SPRING

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

Fig 21: Removing/Installing Low/Reverse Accumulator Snap Ring
Courtesy of CHRYSLER LLC

1 - SNAP RING

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

Fig 22: Removing/Installing Low/Reverse Accumulator Plug
Courtesy of CHRYSLER LLC

1 - ADJUSTABLE PLIERS

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

Fig 23: Low/Reverse Accumulator Piston
Courtesy of CHRYSLER LLC

1 - ACCUMULATOR PISTON
Remove low/reverse accumulator piston (1) using suitable pliers. See Fig 23.

Fig 24: Low/Reverse Accumulator Piston And Springs
Courtesy of CHRYSLER LLC

1 - PISTON

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

Fig 25: Removing/Installing Oil Pump Attaching Bolts
Courtesy of CHRYSLER LLC

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: Removing Oil Pump
Courtesy of CHRYSLER LLC

1 - OIL PUMP

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

Fig 27: Removing Oil Pump While Pushing In On Input Shaft
Courtesy of CHRYSLER LLC

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

Fig 28: Removing/Installing Oil Pump Gasket
Courtesy of CHRYSLER LLC

1 - BELLHOUSING

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

Fig 29: Removing/Installing By-Pass Valve
Courtesy of CHRYSLER LLC

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: Removing/Installing No. 1 Caged Needle Bearing
Courtesy of CHRYSLER LLC

1 - #1 CAGED NEEDLE BEARING

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

Fig 31: Removing/Installing Input Clutch Assembly
Courtesy of CHRYSLER LLC

1 - INPUT CLUTCH ASSEMBLY

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

Fig 32: Identifying #4 Thrust Plate

Courtesy of CHRYSLER LLC

1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

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

Fig 33: View Of Front Sun Gear Assembly And #4 Thrust Washer
Courtesy of CHRYSLER LLC

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: Identifying Front Carrier/Rear Annulus And Needle Bearing

Courtesy of CHRYSLER LLC

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: Removing/Installing Rear Sun Gear
Courtesy of CHRYSLER LLC

1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

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

Fig 36: Identifying Rear Sun Gear & No. 7 Needle Bearing

Courtesy of CHRYSLER LLC

1 - #7 BEARING

2 - REAR SUN GEAR

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. See Fig 36.

Fig 37: Removing 2/4 Clutch Retainer Snap Ring

Courtesy of CHRYSLER LLC

1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE: Verify that Compressor Tool 5058A (1) is centered properly over the 2/4 clutch retainer (4) before compressing. If necessary, fasten the Compressor Tool 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: View Of 2/4 Clutch Retainer & Return Spring
Courtesy of CHRYSLER LLC

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: Removing/Installing 2/4 Clutch Return Spring
Courtesy of CHRYSLER LLC

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

Fig 40: Removing/Installing 2/4 Clutch Pack
Courtesy of CHRYSLER LLC

1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

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

Fig 41: Removing Tapered Snap Ring

Courtesy of CHRYSLER LLC

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: Removing/Installing Low/Reverse Reaction Plate
Courtesy of CHRYSLER LLC

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

Fig 43: Low/Reverse Clutch Disc
Courtesy of CHRYSLER LLC

1 - ONE DISC FROM LOW/REVERSE CLUTCH

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

Fig 44: Removing/Installing Low/Reverse Reaction Plate Snap Ring

Courtesy of CHRYSLER LLC

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: Removing/Installing Low/Reverse Clutch Pack
Courtesy of CHRYSLER LLC

1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

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

Fig 46: Locating Stakes Of Output Shaft Nut

Courtesy of CHRYSLER LLC

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: View Of Stake Grinding Pattern

Courtesy of CHRYSLER LLC

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. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut. See Fig 47.

Fig 48: Opening Nut Stakes
Courtesy of CHRYSLER LLC

1 - CHISEL

2 - NUT STAKE

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

Fig 49: Removing/Installing Output Shaft Nut

Courtesy of CHRYSLER LLC

1 - SPECIAL TOOL 6497

2 - SPECIAL TOOL 6498A

3 - BREAKER BAR

Remove snap ring from output shaft.

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

Fig 50: Removing Output Shaft From Case Using Shop Press

Courtesy of CHRYSLER LLC

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: Removing Front Bearing Cup
Courtesy of CHRYSLER LLC

1 - ARBOR PRESS

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

Fig 52: Removing Rear Output Shaft Bearing Cup
Courtesy of CHRYSLER LLC

1 - SPECIAL TOOL 4171 AND 4171-2

2 - SPECIAL TOOL 6597

Use Wrench 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: Removing Rear Carrier Front Bearing Cone

Courtesy of CHRYSLER LLC

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

Courtesy of CHRYSLER LLC

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: Removing Belleville Spring Snap Ring

Courtesy of CHRYSLER LLC

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: Removing/Installing Low/Reverse Piston Belleville Spring
Courtesy of CHRYSLER LLC

1 - LOW/REVERSE PISTON RETURN SPRING

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

Fig 57: Anchor Shaft Removal
Courtesy of CHRYSLER LLC

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: Removing/Installing Guide Bracket Pivot Pin
Courtesy of CHRYSLER LLC

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: Removing/Installing Low/Reverse Clutch Piston

Courtesy of CHRYSLER LLC

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: Removing/Installing Piston Retainer
Courtesy of CHRYSLER LLC

1 - LOW/REVERSE CLUTCH PISTON RETAINER

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

Fig 61: Removing/Installing Piston Retainer Gasket
Courtesy of CHRYSLER LLC

1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Remove the low/reverse piston retainer gasket (2). See Fig 61.