Part 1

ASSEMBLY

Special Tools:














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 . TCM Quick Learn




Figure 1 - 42RLE BEARING ORIENTATION









1. Install the output bearing cups using Installer. (Figure 2)










2. Install low/reverse piston retainer gasket (2)(Figure 3).










3. Install low/reverse piston retainer (1)(Figure 4).










4. Install low/reverse piston retainer-to-case screws (3) (Figure 5) 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) (Figure 6).










6. Assemble guide bracket (1)(Figure 7) 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)(Figure 8).
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. (Figure 9)










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










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










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










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 (1)(Figure 13).










14. Install Support Plate (1) (Figure 14). 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. Ensure your press table has clearance for the output shaft.










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










17. Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use Disc (2), Universal Handle and Handle Extension (1) to press shaft into rear bearing (Figure 16).










CAUTION: Do not re-use old output shaft nut because the removed stake weakens the nut flange. Using Wrenches 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(Figure 17). 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 (Figure 18). Use Staking Tool (2) to stake output shaft nut.