42RLE Automatic Transmission (Service Information): Disassembly: 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/MODULE, Transmission Control - 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).

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

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339A

Measure input shaft end play using End Play Set 8266A (1, 2). Set up the required items from End Play Set 8266A (1, 2) and a dial indicator C-3339A (3) as shown in illustration.

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 end play exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.

Fig 3: Remove/Install Adapter Housing Bolts

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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

3 - BOLTS

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.

Remove the bolts that hold the adapter or extension housing (2) onto the transmission case.

Fig 4: Remove/Install Adapter Housing
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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING
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: Remove/Install Extension Housing
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1 - TRANSMISSION CASE

2 - EXTENSION HOUSING

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: 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. If the grommet lip is damaged, it will need to be replaced.

On 4X2 transmissions, perform the following, if necessary:

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

Fig 7: Remove/Install Extension Shaft Bearing Snap Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - SNAP RING

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

Fig 8: Remove/Install Extension Shaft and Bearing Assembly

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1 - EXTENSION HOUSING

2 - EXTENSION SHAFT

3 - BEARING

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

Fig 9: Remove/Install Extension Shaft Bearing Retaining Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - RETAINING RING

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

Fig 10: Remove/Install Extension Shaft Bearing

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1 - EXTENSION SHAFT

2 - BEARING

Fig 11: Identifying 4X4 Stub Shaft, Adapter & Slide Hammer

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Using OTC® Slide Hammer 1155 or 7703 (3), or equivalent, and Adapter 10171 (2), remove the 4X4 stub shaft (1).

Fig 12: Remove 4X4 Stub Shaft
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1 - STUB SHAFT

2 - OUTPUT SHAFT
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: 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.

Fig 14: 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.

Fig 15: Remove Output Speed Sensor
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the input and output (2) speed sensors. Identify the speed sensors for reinstallation since they are not interchangeable.

Fig 16: 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) .

Fig 17: Remove/Install Transmission Oil Pan
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1 - TRANSMISSION OIL PAN
Remove the transmission oil pan (1) .

Fig 18: Remove Oil Filter Screws
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1 - OIL FILTER

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

Fig 19: Remove/Install Transmission Filter
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1 - TRANSMISSION FILTER
Remove transmission oil filter (1) .

Fig 20: 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.

Fig 21: Removing/Installing Valve Body Bolts
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1 - BOLTS
Remove valve body-to-case bolts (1) .

Fig 22: Removing/Installing Valve Body
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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.

Fig 23: 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) .

Fig 24: Remove/Install Low/Reverse Accumulator & Snap Ring
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1 - SNAP RING

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

Fig 25: Remove/Install Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

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

Fig 26: Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON
Remove low/reverse accumulator piston (1) using suitable pliers.

Fig 27: Low/Reverse Accumulator
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1 - PISTON

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

Fig 28: Remove/Install Oil Pump Attaching Bolts
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1 - BOLTS

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

Fig 29: Oil Pump Pullers
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1 - OIL PUMP

2 - PULLERS
Remove oil pump using Slide Hammers C-3752 (2) .

Fig 30: 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) .

Fig 31: Remove/Install Oil Pump Gasket
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1 - BELLHOUSING

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

Fig 32: Remove/Install 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) .

Fig 33: Remove/Install 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) .

Fig 34: Remove/Install Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY

Remove the input clutch assembly (1) .

Fig 35: Remove/Install #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) .

Fig 36: Remove/Install 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).

Fig 37: Remove/Install 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) .

Fig 38: Remove/Install 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) .

Fig 39: Number 7 Bearing

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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.

Fig 40: 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 Compressor 5058A (1) is centered properly over the 2/4 clutch retainer (4) before compressing. If necessary, fasten the Compressor 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Install and load Compressor 5058A to remove the 2/4 clutch retainer snap ring (3) .

Fig 41: 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) .

Fig 42: Remove/Install 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch return spring (1) .

Fig 43: Remove/Install 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

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

Fig 44: 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) .

Fig 45: Remove/Install Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove the low/reverse reaction plate (1) .

Fig 46: Remove/Install 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.

Fig 47: Remove/Install 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) .

Fig 48: Remove/Install Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

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

Fig 49: 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.

WARNING: Wear safety goggles while grinding stake nuts.

Fig 50: 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 in illustration. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Fig 51: Opening Nut Stakes
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1 - CHISEL

2 - NUT STAKE

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

Fig 52: Remove Output Shaft Nut

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1 - WRENCH 6497

2 - SOCKET WRENCH 6498A

3 - BREAKER BAR

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

Fig 53: 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).

Fig 54: Remove Front Bearing Cup - Typical
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1 - ARBOR PRESS

2 - REMOVER 6596
Use Remover 6596 (2) with a shop press (1) to remove the front output shaft bearing cup.

Fig 55: Remove Rear Bearing Cup
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1 - UNIVERSAL HANDLE C-4171 AND HANDLE EXTENSION C-4171-2

2 - DISK 6597

Use Disc 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: 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) .

Fig 57: Compressor Tool in Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - COMPRESSOR 5058A-3

4 - COMPRESSOR 5059-A

5 - DISC 6057

Install and load Compressor 5059-A (4) , Compressor 5058A (3), and Disc 6057 (5) as shown in illustration.

Fig 58: Remove Snap Ring

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

2 - SNAP RING PLIERS

3 - COMPRESSOR 5059-A

Remove the low/reverse Belleville spring snap ring (1) .

Fig 59: 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) .

Fig 60: 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) .

Fig 61: Identifying Guide Bracket Pivot Shaft & Pin
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

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

Fig 62: Remove/Install 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) .
Remove the low/reverse piston retainer screws.

Fig 63: Remove/Install Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

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

Fig 64: Remove/Install 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) .