Part 1

ASSEMBLY

NOTE: Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) ATF +4. Soak all friction disks in MOPAR(R) ATF +4 for at least two hours before assembly of clutch packs.

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 Quick Learn Procedure .




42RLE BEARING ORIENTATION









1. Install the output bearing cups using Installer 5050A.










2. Install low/reverse piston retainer gasket (2).










3. Install low/reverse piston retainer (1).










4. Install low/reverse piston retainer-to-case screws (3) and tighten to 5 Nm (45 in. lbs.).










NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

5. Install low/reverse clutch piston (1).










6. Assemble guide bracket (1) assembly as shown, if necessary.










CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case.

7. Install guide bracket pivot pin (1).
8. Install park sprag pivot retaining bolt and torque to 4.5 Nm (40 in. lbs.).










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










10. Install and load low/reverse spring compressor tools (Compressors 5058A-3 and 5059-A and Disc 6057) (3, 4, 5) as shown to facilitate snap ring (2) installation.










11. Install snap ring (1) and remove the tools.










12. Install rear carrier (4) front bearing cone.










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

13. PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and Support Plate 6618A (1).










14. Install Support Plate 6618A (1). Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
15. 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 6618A. Ensure your press table has clearance for the output shaft.










16. Install shim (1) on output shaft (2). 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.










17. Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use Disc MD-998911 (2), Universal Handle C-4171 and Handle Extension C-4171-2 (1) to press shaft into rear bearing.










CAUTION: Do not re-use old output shaft nut because the removed stake weakens the nut flange. Using Wrenches 6497 and 6498A, install new output shaft nut. Tighten new output shaft nut to 271 Nm (200 ft. lbs.).

18. Check the turning torque (1) of the output shaft. The shaft should have 1-8 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 1in.lb., install a thinner shim. Make sure there is no end play.










CAUTION: Failure to stake nut could allow the nut to back-off during use.

19. The new nut (3) must be staked after the correct turning torque is obtained. Use Staking Tool 6639 (2) to stake output shaft nut.










20. Verify that the nut has been properly staked to the output shaft.
21. Install the snap ring onto the output shaft.










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










23. Install low/reverse reaction plate snap ring (2).










24. Install one low/reverse clutch disc (1).










25. Install low/reverse reaction plate (1) with flat side up.










26. Install a new tapered snap ring (2) (tapered side out).





27. Make sure that the snap ring ends are oriented as shown.










28. Measure low/reverse clutch pack. Set up Dial Indicator C-3339A (1) as shown. 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).
29. Select the proper low/reverse reaction plate to achieve specifications.










30. Install 2/4 clutch pack (1, 2).










NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

31. Install 2/4 clutch belleville spring (1).










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










33. Install 2/4 clutch retainer (1).










NOTE: Verify that Compressor 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.

34. Set up Compressor 5058A (1) as shown. Compress 2/4 clutch just enough to facilitate snap ring installation.