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 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: Identifying 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). Refer to Fig 1.

Fig 2: Measuring Input Shaft End Play

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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 (special tool #8266B, End Play Socket Set) (1, 2). Set up the required items from End Play Set (special tool #8266B, End Play Socket Set) (1, 2) and a dial indicator (special tool #C-3339A, Set, Dial Indicator) (3) as shown in illustration. Refer to Fig 2.

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 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. Refer to Fig 3.

Fig 4: Remove Adapter Housing
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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING
Remove the adapter (2) housing, 4X4 vehicles only, from the transmission case. Refer to Fig 4. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.

Fig 5: Identifying Extension Housing
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1 - TRANSMISSION CASE

2 - EXTENSION HOUSING

Remove the extension (2) housing, 4X2 vehicles only, from the transmission case. Refer to Fig 5. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.

Fig 6: Identifying 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 (3) for damage. Refer to Fig 6. If the grommet lip is damaged, it will need to be replaced.

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

Fig 7: Identifying Extension Shaft Bearing Snap Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - SNAP RING

Remove the extension shaft bearing snap ring (3) from the extension housing. Refer to Fig 7.

Fig 8: Identifying Extension Shaft & Bearing Assembly

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1 - EXTENSION HOUSING

2 - EXTENSION SHAFT

3 - BEARING

Remove the extension shaft and bearing assembly (2) from the extension housing (1). Refer to Fig 8.

Fig 9: Identifying Extension Shaft Bearing Retaining Ring

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1 - EXTENSION SHAFT

2 - BEARING

3 - RETAINING RING

Remove the extension shaft bearing retaining ring (3) from the extension shaft (1). Refer to Fig 9.

Fig 10: Identifying Extension Shaft Bearing

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1 - EXTENSION SHAFT

2 - BEARING

Remove the extension shaft bearing (2) from the extension shaft (1). Refer to Fig 10.

Fig 11: Removing 4x4 Stub Shaft

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

Fig 12: Removing 4x4 Stub Shaft
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1 - STUB SHAFT

2 - OUTPUT SHAFT
Remove the 4X4 stub shaft (1) from the transmission output shaft. Refer to Fig 12. Inspect the cir-clip on the shaft for damage and replace the clip if necessary.

Fig 13: Identifying 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. Refer toFig 13.

Fig 14: Identifying 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. Refer toFig 14.

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

2 - TRANSMISSION CASE
Remove the input and output (2) speed sensors. Refer to Fig 15. Identify the speed sensors for re-installation since they are not interchangeable.

Fig 16: Identifying 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). Refer to Fig 16.

Fig 17: Identifying Transmission Oil Pan
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1 - TRANSMISSION OIL PAN
Remove the transmission oil pan (1). Refer to Fig 17.

Fig 18: Identifying Oil Filter Screws
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1 - OIL FILTER

2 - SCREWS
Remove the transmission oil filter screws (2). Refer to Fig 18.

Fig 19: Identifying Transmission Filter
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1 - TRANSMISSION FILTER
Remove transmission oil filter (1). Refer to Fig 19.

Fig 20: Locating 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. Refer to Fig 20.

Fig 21: Identifying Valve Body Bolts
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1 - BOLTS
Remove valve body-to-case bolts (1). Refer to Fig 21.

Fig 22: Identifying 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. Refer to Fig 22.

Fig 23: Identifying 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). Refer to Fig 23.

Fig 24: Remove Low/Reverse Accumulator
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Remove the low/reverse accumulator snap ring (1). Refer to Fig 24.

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

2 - PLUG
Remove the low/reverse accumulator plug (2). Refer to Fig 25.

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

Fig 27: Low/Reverse Accumulator Piston & Springs
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1 - PISTON

2 - RETURN SPRINGS
Remove piston (1) and springs (2). Refer to Fig 27.

Fig 28: Identifying Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP
Remove and discard the oil pump-to-case bolts (1). Refer to Fig 28. 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 (special tool #C-3752, Slide Hammers) (2). Refer to Fig 29.

Fig 30: Removing Oil Pump While Pushing In On Input Shaft
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
Remove oil pump while pushing in on input shaft (1). Refer to Fig 30.

Fig 31: Identifying Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Remove oil pump gasket (2). Refer to Fig 31.

Fig 32: Identifying 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). Refer to Fig 32.

Fig 33: Installing Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove the #1 caged needle bearing (1). Refer to Fig 33.

Fig 34: Installing Input Clutch Assembly With Proper Thrust Plate
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1 - INPUT CLUTCH ASSEMBLY

Remove the input clutch assembly (1). Refer to Fig 34.

Fig 35: Installing 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). Refer to Fig 35.

Fig 36: Removing/Installing Front Sun Gear Assembly And #4 Thrust Washer
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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). Refer to Fig 36.

Fig 37: 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). Refer to Fig 37.

Fig 38: Removing/Installing 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). Refer to Fig 38.

Fig 39: Identifying Rear Sun Gear

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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. Refer to Fig 39. 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 Snap Ring

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1 - TOOL 5058

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 Compressor (special tool #5058A, Compressor, Spring) bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Install and load Compressor (special tool #5058A, Compressor, Spring) to remove the 2/4 clutch retainer snap ring (3). Refer to Fig 40.

Fig 41: Removing 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). Refer to Fig 41.

Fig 42: Installing 2/4 Clutch Belleville Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch return spring (1). Refer to Fig 42.

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

2 - CLUTCH DISC (4)

Remove the 2/4 clutch pack (1, 2). Refer to Fig 43.

Fig 44: Removing 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). Refer to Fig 44.

Fig 45: Installing Low/Reverse Reaction Plate With Flat Side Up
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove the low/reverse reaction plate (1). Refer to Fig 45.

Fig 46: Installing One Low/Reverse Clutch Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove one (1) low/reverse clutch disc to facilitate snap ring removal. Refer toFig 46.

Fig 47: Installing 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). Refer to Fig 47.

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

2 - CLUTCH DISCS (5)

Remove the low/reverse clutch pack (1, 2). Refer to Fig 48.

Fig 49: Grinding To Open Staking On Output Shaft Nut

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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. Refer to Fig 49.

WARNING:

Wear safety goggles while grinding stake nuts.

Fig 50: Grinding Stakes In Shoulder Of Shaft Nut

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

Fig 51: Opening Stakes On Nut
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1 - CHISEL

2 - NUT STAKE

Using a small chisel (1), carefully open the stakes on nut (2). Refer to Fig 51.

Fig 52: Identifying Output Shaft Nut

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1 - WRENCH 6497

2 - SOCKET WRENCH 6498A

3 - BREAKER BAR

Use Wrench (special tool #6497, Wrench, Transfer Shaft) (1) and Socket Wrench (special tool #6498A, Wrench, Socket) (2) to remove the output shaft nut. Refer to Fig 52.

Fig 53: Removing Output Shaft From Case Using Shop Press

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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). Refer to Fig 53.

Fig 54: Removing Front Output Shaft Bearing Cup
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1 - ARBOR PRESS

2 - REMOVER 6596
Use Remover (special tool #6596, Remover, Bearing Cup) (2) with a shop press (1) to remove the front output shaft bearing cup. Refer to Fig 54.

Fig 55: Pressing Rear Output Shaft Bearing Cup
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1 - UNIVERSAL HANDLE C-4171 AND HANDLE EXTENSION C-4171-2

2 - DISK 6597

Use Disc (special tool #6597, Remover, Bearing Cup) (2) and Universal Handle (special tool #C-4171, Driver Handle, Universal) (1) and Handle Extension (special tool #C-4171-2, Extension, Drive Handle) to press the rear output shaft bearing cup rearward. Refer to Fig 55.

Fig 56: Removing 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). Refer to Fig 56.

Fig 57: Installing And Load 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 Compressor (special tool #5059-A, Compressor, Spring) (4), Compressor (special tool #5058A, Compressor, Spring) (3), and Disc (special tool #6057, Disc, Spring Compressor) (5) as shown in illustration. Refer to Fig 57.

Fig 58: Removing Low/Reverse Belleville Spring Snap Ring

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

2 - SNAP RING PLIERS

3 - COMPRESSOR 5059-A

Remove the low/reverse belleville spring snap ring (1). Refer to Fig 58.

Fig 59: Installing Low/Reverse Piston Belleville Spring Into Position
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON
Remove the low/reverse piston belleville spring (1). Refer to Fig 59.

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). Refer to Fig 60.

Fig 61: Installing Guide Bracket Pivot Pin
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

Remove the guide bracket pivot pin (1). Refer to Fig 61. Inspect all components for wear and replace if necessary.

Fig 62: Identifying 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). Refer to Fig 62.
Remove the low/reverse piston retainer screws.

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

2 - GASKET
Remove low/reverse piston retainer (1). Refer to Fig 63.

Fig 64: Installing Low/Reverse 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). Refer to Fig 64.