Steps 1 thru 25

42LE - Automatic Transaxle
ASSEMBLY
Steps 1 - 25


NOTE: If the transaxle assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIII (R) Scan Tool.







1. Install the output bearing cups, use Special Tool # 5050A (Fig. 78).







2. Install low/reverse piston retainer gasket (Fig. 79).







3. Install low/reverse piston retainer (Fig. 80).







4. Install low/reverse piston retainer-to-case screws (Fig. 81) and torque to 5 Nm (45 inch lbs.).







5. Install low/reverse clutch piston (Fig. 82).










6. Assemble guide bracket assembly as shown in (Fig. 83) (Fig. 84).







7. Install guide bracket pivot shaft (Fig. 85).

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







8. Install park sprag pivot retaining screw (Fig. 86) and torque to 5 Nm (45 inch lbs.).







9. Install low/reverse piston belleville spring into position (Fig. 87).










10. Install and load low/reverse spring compressor tool as shown in (Fig. 88) (Fig. 89) to facilitate snap ring installation.







11. Install snap ring and remove compressor tool (Fig. 90).







12. Install rear carrier front bearing cone (Fig. 91).
13. 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
- Transaxle case







a. PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and special tool 6618A (Fig. 92).







b. Install special tool 6618A (Fig. 93). Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
c. 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 tool 6618A. Ensure your press table has clearance for the output shaft.







d. Install shim on output shaft (Fig. 94). 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. Refer to Output Shaft Rear Shim Chart for available sizes.







e. Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD998911 (Disc) and C- 4171 and C4171-2 (Handle) to press shaft into rear bearing (Fig. 95).
f Do not re-use old transfer shaft nut or output shaft nut because the removed stake weakens the nut flange. Using special tools 6497 and 6498, install new output shaft nut. Do not reuse old output shaft nut. Tighten new output shaft nut to 271 Nm (200 ft. lbs.).







g. Check the turning torque of the output shaft (Fig. 96). The shaft should have 1 to 8 inch lbs. of turning torque. If the turning torque is higher than 8 inch 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.










h. The new nut must be staked after the correct turning torque is obtained (Fig. 97) (Fig. 98). Use special tool 6639 to stake output shaft nut and special tool 6589 to stake transfer shaft.


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










14. Apply Mopar ATF RTV (MS-GF41) as shown in (Fig. 99). Install main sump baffle to transaxle case (Fig. 100) and torque screw to 5 Nm (45 inch lbs.).

CAUTION: When reinstalling drive chains, the blue link must face outward.







15. Install output sprocket spacer (Fig. 101).


CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, installation will be difficult.







16. Install transfer chain and sprockets to transfer shaft and output shaft (Fig. 102).







17. Remove chain spreader (Fig. 103).










18. Install transfer shaft sprocket snap rings and wave washers (Fig. 104) (Fig. 105).

CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.







19. Install transfer chain snubber (Fig. 106) and torque screws to 5 Nm (45 inch lbs.).







20. Install chain oiler (Fig. 107) and torque screw to 5 Nm (45 inch lbs.).
21. Stand trans upright on bellhousing.







22. Install chain cover (Fig. 108). Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of Mopar ATF RTV (MS-GF41) to flange of cover.







23. Install low/reverse clutch pack (Fig. 109). Leave uppermost disc out to facilitate snap ring installation.







24. Install low/reverse reaction plate snap ring (Fig. 110).







25. Install one low/reverse clutch disc (Fig. 111).