42RLE Automatic Transmission (Service Information): Assembly: 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 MODULE, TRANSMISSION CONTROL, STANDARD PROCEDURE .

Fig 1: 42RLE Bearing Orientation

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1 - THRUST BEARING NO. 1	5 - THRUST BEARING NO. 5
2 - THRUST BEARING NO. 2	6 - NEEDLE BEARING NO. 6
3 - THRUST BEARING NO. 3	7 - NEEDLE BEARING NO. 7
4 - THRUST BEARING NO. 4

Fig 2: Bearing Cup Installer

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Install the output bearing cups using Installer (special tool #5050A, Installer, Bearing Cup). Refer to Fig 2.

Fig 3: Low/Reverse Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Install low/reverse piston retainer gasket (2). Refer to Fig 3.

Fig 4: Low/Reverse Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET

Install low/reverse piston retainer (1). Refer to Fig 4.

Fig 5: Installing Low/Reverse Piston Retainer-To-Case Screws

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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - SCREWDRIVER

3 - TORX-LOC SCREWS

Install low/reverse piston retainer-to-case screws (3) and torque to 5 N.m (45 in. lbs.). Refer to Fig 5.

Fig 6: 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.

Install low/reverse clutch piston (1). Refer to Fig 6.

Fig 7: Assembling Guide Bracket Assembly

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1 - GUIDE BRACKET

2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN IN ILLUSTRATION)

3 - PAWL

Assemble guide bracket (1) assembly as shown in illustration, if necessary. Refer to Fig 7.

Fig 8: Guide Bracket Pivot Pin
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

CAUTION:
When installing, be sure guide bracket and split sleeve touch the rear of the transmission case.
Install guide bracket pivot pin (1). Refer to Fig 8.
Install park sprag pivot retaining screw and torque to 4.5 N.m (40 in. lbs.).

Fig 9: Low/Reverse Piston Belleville Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

Install low/reverse piston belleville spring (1) into position. Refer to Fig 9.

Fig 10: Installing & Loading 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 low/reverse spring with compressor tool (special tool #5058A-3, Screw, Forcing) (3), (special tool #5059-A, Compressor, Spring) (4) and disc (special tool #6057, Disc, Spring Compressor) (5) as shown in illustration to facilitate snap ring (2) installation. Refer to Fig 10.

Fig 11: Installing Snap Ring

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

2 - SNAP RING PLIERS

3 - DISC 6057

Install snap ring (1) and remove compressor tool. Refer to Fig 11.

Fig 12: Installing Rear Carrier Front Bearing Cone

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1 - ARBOR PRESS

2 - UNIVERSAL HANDLE C-4171

3 - INSTALLER 6052

4 - REAR CARRIER

Install rear carrier (4) front bearing cone. Refer to Fig 12.

Fig 13: Bearing & Support Plate
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1 - SUPPORT PLATE 6618A

2 - REAR OUTPUT SHAFT BEARING

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 (special tool #6618A, Plate, Bearing Installer) (1). Refer to Fig 13.

Fig 14: Installing Support Plate
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1 - SUPPORT PLATE 6618A
Install Support Plate (special tool #6618A, Plate, Bearing Installer) (1). Refer to Fig 14. 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 (special tool #6618A, Plate, Bearing Installer). Ensure your press table has clearance for the output shaft.

Fig 15: Installing Shim On Output Shaft
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1 - SHIM

2 - OUTPUT SHAFT
Install shim (1) on output shaft (2). Refer to Fig 15. 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 16: Installing Output Shaft/Rear Carrier Into Rear Bearing
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1 - UNIVERSAL HANDLE C-4171 AND HANDLE EXTENSION C-4171-2

2 - DISC MD-998911

Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use Disc (special tool #MD-998911, Installer, Bearing) (2) and Universal Handle (special tool #C-4171, Driver Handle, Universal) and Handle Extension (special tool #C-4171-2, Extension, Drive Handle) (1) to press shaft into rear bearing. Refer to Fig 16.

Fig 17: Installing Output Shaft Nut

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1 - TORQUE WRENCH

2 - WRENCH 6498A

3 - OUTPUT SHAFT NUT

CAUTION:

Do not re-use old output shaft nut because the removed stake weakens the nut flange. Using Wrenches (special tool #6497, Wrench, Transfer Shaft) and 6498A, 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. Refer to Fig 17. 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 18: Staking Output Shaft Nut

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1 - ARBOR PRESS

2 - STAKING TOOL - 6639

3 - NEW NUT

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. Refer to Fig 18. Use Staking Tool (special tool #6639, Tool, Staking) (2) to stake output shaft nut.

Fig 19: Identifying Correctly Staked Nut
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1 - BOTTOMED IN SLOT

2 - CORRECTLY STAKED NUT
Verify that the nut has been properly staked to the output shaft. Refer to Fig 19.

Fig 20: Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Install low/reverse clutch pack (1, 2). Refer to Fig 20. Leave uppermost disc out to facilitate snap ring installation.

Fig 21: 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

Install low/reverse reaction plate snap ring (2). Refer to Fig 21.

Fig 22: Low/Reverse Clutch Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH
Install one low/reverse clutch disc (1). Refer to Fig 22.

Fig 23: Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Install low/reverse reaction plate (1) with flat side up. Refer to Fig 23.

Fig 24: Installing Tapered Snap Ring
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1 - SCREWDRIVER

2 - TAPERED SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
Install a new tapered snap ring (2) (tapered side out). Refer to Fig 24.

Fig 25: Proper Snap Ring Orientation
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Make sure that the snap ring ends are oriented as shown in illustration. Refer to Fig 25.

Fig 26: Checking Low/Reverse Clutch Clearance

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1 - DIAL INDICATOR

2 - DIAL INDICATOR TIP TOOL 6268

3 - HOOK TOOL

Measure low/reverse clutch pack. Set up dial indicator (1) as shown in illustration. Refer to Fig 26. 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 27: 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)
Install 2/4 clutch pack (1, 2). Refer to Fig 27.

Fig 28: 2/4 Clutch Return Spring
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1 - 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.

Install 2/4 clutch belleville spring (1). Refer to Fig 28.

Fig 29: View Of Proper Orientation Of 2/4 Clutch Retainer & Spring

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1 - NOTE POSITION

2 - RETURN SPRING

3 - 2/4 CLUTCH RETAINER

Verify the proper orientation of the return spring (2) to the 2/4 retainer (3). Refer to Fig 29.

Fig 30: Installing 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

Install 2/4 clutch retainer (1). Refer to Fig 30.

Fig 31: 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) (1) is centered properly over the 2/4 clutch retainer (4) before compressing. If necessary, fasten the bar from Compressor (special tool #5058A, Compressor, Spring) to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Set up Compressor (special tool #5058A, Compressor, Spring) (1) as shown in illustration. Refer to Fig 31. Compress 2/4 clutch just enough to facilitate snap ring installation.

Fig 32: Checking 2/4 Clutch Clearance

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1 - DIAL INDICATOR

2 - HOOK TOOL

3 - DIAL INDICATOR TIP TOOL 6268

Measure 2/4 clutch clearance: Set up dial indicator (1) as shown in illustration. Refer to Fig 32. 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 33: #7 Bearing & Rear Sun Gear
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1 - #7 BEARING

2 - REAR SUN GEAR
Install the #7 needle bearing (1) to the rear sun gear (2). Refer to Fig 33. 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 34: Rear Sun Gear & #7 Needle Bearing
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Install rear sun gear (2) and #7 needle bearing (1). Refer to Fig 34.

Fig 35: 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).

Install front carrier/rear annulus assembly (2) and #6 needle bearing (1). Refer to Fig 35.

Fig 36: Front Sun Gear Assembly & No. 4 Thrust Washer
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Install front sun gear assembly (1) and #4 thrust washer (2). Refer to Fig 36.

Fig 37: #4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate.
Install #4 thrust plate (2) using petrolatum to hold into position. Refer to Fig 37.
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 38: Removing Oil Pump O-Ring
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1 - OIL PUMP ASSEMBLY

2 - O-RING

Remove the oil pump o-ring (2) and install oil pump and gasket to transmission. Refer to Fig 38. 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 39: Measuring Input Shaft End Play

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339A

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 (special tool #8266B, End Play Socket Set) (1, 2) and Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (3) as shown in illustration. Refer to Fig 39.
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 40: Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY
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. Refer to Fig 40.

Fig 41: No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Install #1 caged needle bearing (1). Refer to Fig 41.

Fig 42: By-Pass Valve
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1 - BYPASS VALVE

CAUTION:
By-pass valve MUST be replaced if transmission failure occurs.
Replace cooler by-pass valve (1) if transmission failure has occurred. Refer to Fig 42.
NOTE:
To align oil pump, gasket, and case during installation, use threaded dowels or Phillips screwdrivers.

Fig 43: Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Install oil pump gasket (2). Refer to Fig 43.

Fig 44: Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP
Install oil pump (2) and torque oil pump-to-case bolts (1) to 30 N.m (265 in. lbs.). Refer to Fig 44. Do not reuse original oil pump bolts.

Fig 45: Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON
Install low/reverse accumulator (1) as shown in illustration. Refer to Fig 45.

Fig 46: Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Install low/reverse accumulator plug (2). Refer to Fig 46.

Fig 47: Low/Reverse Accumulator & Snap Ring
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Install low/reverse accumulator snap ring (1). Refer to Fig 47.

Fig 48: Underdrive & Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Install underdrive (2) and overdrive (1) accumulators and springs. Refer to Fig 48.

Fig 49: Valve Body
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1 - VALVE BODY

CAUTION:
Do not handle the valve body by the manual shaft. Damage could result.
Install valve body (1) into place as shown in illustration. Refer to Fig 49.

Fig 50: Valve Body Bolts
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1 - BOLTS
Install seven (7) valve body-to-case bolts (1) and torque to 12 N.m (105 in. lbs.). Refer to Fig 50.

Fig 51: Transmission Filter
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1 - TRANSMISSION FILTER
Install transmission oil filter (1). Refer to Fig 51. Tighten the bolts to 5 N.m (45 in. lbs.).

Fig 52: Transmission Oil Pan
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1 - TRANSMISSION OIL PAN

Install transmission oil pan (1) with a bead of Mopar® ATF RTV. Refer to Fig 52.

Fig 53: Pressure Ports, Oil Pan & Bolts

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1 - FRONT DRIVESHAFT

2 - PRESSURE PORTS

3 - TRANSMISSION CASE

4 - TRANSMISSION OIL PAN

5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE

6 - FIRST TRANSMISSION OIL PAN BOLT

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 Mopar® Lock AND Seal Adhesive. Refer to Fig 53.

Install and torque the oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.).

Fig 54: Input Speed, Output Speed & Transmission Range Sensors

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1 - INPUT SPEED SENSOR

2 - OUTPUT SPEED SENSOR

3 - TRANSMISSION RANGE SENSOR

NOTE:

Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock AND Seal Adhesive.

Install both speed sensors (1, 2) into the transmission case. Refer to Fig 54. Torque the speed sensor bolts to 9 N.m (80 in. lbs.).

Fig 55: Measuring Input Shaft End Play

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339A

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 (special tool #C-3339A, Set, Dial Indicator) to transmission bell housing with its plunger seated against end of input shaft. Refer to Fig 55. Install tool (special tool #8266-2, Spline Tool, 42LE) (2), (special tool #8266-8, Handle) (1) and 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 56: Extension Shaft Bearing

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1 - EXTENSION SHAFT

2 - BEARING

Install the extension shaft bearing (2) onto the extension shaft. Refer to Fig 56.

Fig 57: Extension Shaft Bearing Retaining Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - RETAINING RING

Install the extension shaft bearing retaining ring (3) onto the extension shaft (1). Refer to Fig 57.

Fig 58: Extension Shaft & Bearing Assembly

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1 - EXTENSION HOUSING

2 - EXTENSION SHAFT

3 - BEARING

Install the extension shaft (2) and bearing assembly (3) into the extension housing (1). Refer to Fig 58.

Fig 59: Extension Shaft Bearing Snap Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - SNAP RING

Install the extension shaft bearing snap ring (3) into the extension housing. Refer to Fig 59.

Fig 60: Extension Shaft Bearing Snap Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - SNAP RING

Verify that the extension shaft snap ring (3) is fully engaged in the snap ring groove. Refer to Fig 60.

Fig 61: 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 (2) for damage. Refer to Fig 61. If the grommet lip is damaged, it will need to be replaced.

Fig 62: Transmission Case & Adapter Housing
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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING
Install the 4X4 stub shaft onto the transmission output shaft.
Place a bead of Mopar® 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. Refer to Fig 62.

Fig 63: Transmission Case & Extension Housing
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1 - TRANSMISSION CASE

2 - EXTENSION HOUSING

Install the extension housing (2) onto the transmission case, 4X2 vehicles only. Refer to Fig 63.

Fig 64: Installing Adapter/Extension Housing Bolts

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1 - STUD, ADAPTER/EXTENSION

2 - TRANSMISSION MOUNT FASTENERS (4)

3 - TRANSMISSION MOUNT

4 - TRANSMISSION CASE

5 - NUT, EXHAUST HANGER BRACKET (2)

6 - STUD, ADAPTER/EXTENSION

7 - TRANSMISSION OIL PAN

8 - BOLT, ADAPTER/EXTENSION (2)

NOTE:

Before installing the lowermost four adapter/extension housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mopar® Lock AND Seal Adhesive.

Fig 65: Transmission Case, Adapter Housing & Bolts

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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

3 - BOLTS

Install the bolts that hold the adapter or extension housing onto the transmission case. Refer to Fig 65. Be sure to install any stud bolts to their original locations. Tighten the bolts to 54 N.m (40 ft.lbs.).