A/T - 41TE (A604), 42LE Overdrive Clutch Hub/Improved
DATE: 1996TECHNICAL BULLETIN # 321
TRANSMISSION: 41TE(A604), 42LE
SUBJECT: Parts Change
APPLICATION: Chrysler
41TE (A6O4) and 42LE
A change was made in the overdrive clutch hub area in 996 and later model 41 TE and 42LE transaxles (figure one). This change was made to keep the shaft section of the hub assembly from cracking or breaking away from the hub.
Part changes include:
1. The overdrive clutch hub shaft section outer diameter was increased from 1.142" to 1.162". The bottom of the splines machined into the end of the shaft no longer have a back cut to prevent the shaft from bottoming out in the splined planet ID (figure 2).
2. The 2-4 sun gear bushings inside diameter was increased from 1.144" to 1.164" (figure 3).
3. The splines cut into the inside diameter of the front planet (figure 4) have been machined to allow the new O/D clutch hub splines, which now have no back-cut beneath the splines, to engage fully into the planet.
Interchangeability:
A matched early or late set of all three parts, including the O/D clutch hub, 2-4 sun gear hub and the front planet, will fit in any 4lTE or 42LE.
The new O/D clutch hub and 2-4 sun gear hub will not individually interchange with the previous version of these parts. The earlier O/D and 2-4 hubs can be used as a set with the late front planet, but are weaker than the new hubs and may fail in operation. The new, larger hubs can be used as a set with the earlier front planet, provided that the new set of hubs pass the Planet spline conflict test described below.
Planet spline conflict test:
A potential problem can exist when using the newer, larger O/D clutch hub and 2-4 sun gear hub described above with an older version front planet. The earlier planet splines have not been machined in a manner that will assure no spline conflict between the O/D clutch hub shaft and the splines inside the front planet. Therefore, a test must be performed to ensure that a conflict does not exist.
Stack the O/D clutch hub and the 2-4 sun gear hub together on the bench, including both washers that separate them in place (figure 5). Make sure that the 2-4 sun gear hub washer tabs go through the appropriate holes in the hub (figure 6).
Lower the front planet in its normal direction onto the hub splines (figure 7). Press down on the planet with one hand while turning the 2-4 sun gear hub. The hub must be a bit harder to turn when pressing down on the planet, as opposed to when not pressing down on the planet.
While pressing on the planet, also make certain that there is absolutely no up and down end play on the 2-4 sun gear hub. It should be solidly held between the planet and O/D clutch hub, allowing rotation of the sun gear hub only.
Firmly pick up and lower the planet over the hub splines several times, making certain that the planet has absolutely no tendency to stick against the sun gear hub. A solid thunk should be felt whenever the planet thrust bearing contacts the end of the 2-4 sun gear, indicating full contact between the gear and bearing.