automatic transmission DODGE RAM 2001 Service Repair Manual

CONDITION POSSIBLE CAUSES CORRECTION
11. Pump Seal Leaks/Worn/
Damaged.11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION IN
FOURTH GEAR ONLY1. Overdrive Clutch Discs, Plates or
Snap Rings Damaged.1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.2. Remove and disassemble unit. Replace
either thrust bearing if damaged.
3. Output Shaft Bearings Scored/
Damaged.3. Remove and disassemble unit. Replace
either bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning Clutch
Rollers Worn/Scored.5. Remove and overhaul overdrive unit.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppliers.
REMOVAL
The overdrive unit can be removed and serviced
separately. It is not necessary to remove the entire
transmission assembly to perform overdrive unit
repairs.
(1) Disconnect battery negative cable.
(2) Disconnect and lower or remove necessary
exhaust components.
(3) Remove engine-to-transmission struts, if
equipped (Fig. 13).
(4) Disconnect fluid cooler lines at transmission.
(5) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(6) Disconnect and remove the crankshaft position
sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain the sensor attaching bolts.
(7) Remove torque converter access cover.
(8)
If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal (Fig. 13). On
4 x 4 models, it will also be necessary to remove boltattaching transfer case vent tube to converter hous-
ing (Fig. 14).
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts. (Refer to 3 - DIFFERENTIAL & DRIV-
Fig. 13 Transmission-To-Engine Strut Attachment
1 - ENGINE BLOCK
2 - STRUT (PASSENGER SIDE)
3 - ENGINE MOUNT
4 - STRUT (DRIVER SIDE)
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 159
AUTOMATIC TRANSMISSION - 42RE (Continued)

ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(12) Disconnect wires from park/neutral position
switch and transmission solenoid.
(13) Disconnect gearshift rod and torque shaft
assembly from transmission.
(14) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever.
(15) On4x4models, disconnect shift rod from
transfer case shift lever.
(16)
Support rear of engine with safety stand or jack.
(17) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(18) Remove bolts securing rear support and cush-
ion to transmission and crossmember. Raise trans-
mission slightly, slide exhaust hanger arm from
bracket (Fig. 15) and remove rear support.
(19) Remove bolts attaching crossmember to frame
and remove crossmember.
(20) On4x4models, remove transfer case with
transmission jack or aid of helper.
(21) Remove all converter housing bolts.
(22) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(23) Lower transmission and remove assembly
from under the vehicle.
(24) To remove torque converter, remove C-clamp
from edge of bell housing and carefully slide torque
converter out of the transmission.
DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
operations.
(2) Place transmission in a vertical position.(3)
Measure input shaft end play as follows (Fig. 16).
(a) Attach Adapter 8266-6 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c)
Install the assembled tool onto the input shaft
of the transmission and tighten the retaining screw
on Adapter 8266-6 to secure it to the input shaft.
(d)Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indicator.
(e) Move the input shaft in and out. Record the
maximum travel for assembly reference.
Fig. 14 Fill Tube Attachment
1 - TRANSFER CASE VENT TUBE
2 - FILL TUBE (V8)
3 - TUBE SEAL
4 - FILL TUBE (V6)Fig. 15 Rear Support Cushion
1 - EXHAUST PIPE ARM AND BRACKET
2 - CROSSMEMBER
3 - REAR SUPPORT AND CUSHION
Fig. 16 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
21 - 160 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

(4) Remove shift and throttle levers from valve
body manual lever shaft.
(5) Place transmission in horizontal position.
(6) Remove transmission oil pan and gasket.
(7)
Remove filter from valve body (Fig. 17). Keep fil-
ter screws separate from other valve body screws. Filter
screws are longer and should be kept with filter.
(8) Remove park/neutral position switch.
(9)
Remove hex head bolts attaching valve body to
transmission case (Fig. 18). A total of 10 bolts are used.
Note different bolt lengths for assembly reference.
(10) Remove valve body assembly. Push valve body
harness connector out of case. Then work park rod
and valve body out of case (Fig. 19).
(11) Remove accumulator piston and inner and
outer springs (Fig. 20).
(12) Remove pump oil seal with suitable pry tool
or slide-hammer mounted screw.
Fig. 18 Valve Body Bolt Locations
1 - VALVE BODY BOLTS
2 - VALVE BODY BOLTS
Fig. 17 Oil Filter Removal
1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)
Fig. 19 Valve Body Removal
1 - GOVERNOR PRESSURE SENSOR
2 - VALVE BODY
3 - PARK ROD
4 - ACCUMULATOR PISTON
5 - GOVERNOR PRESSURE SOLENOID
Fig. 20 Accumulator Piston And Springs
1 - ACCUMULATOR PISTON
2 - OUTER SPRING
3 - INNER SPRING
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 161
AUTOMATIC TRANSMISSION - 42RE (Continued)

(13) Loosen front band adjusting screw locknut 4-5
turns. Then tighten band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
(14) Remove oil pump bolts.
(15) Thread bolts of Slide Hammer Tools C-3752
into threaded holes in pump body flange (Fig. 21).
(16) Bump slide hammer weights outward to
remove pump and reaction shaft support assembly
from case (Fig. 21).
(17) Loosen front band adjusting screw until band
is completely loose.
(18) Squeeze front band together and remove band
strut (Fig. 22).
(19) Remove front band lever (Fig. 23).
(20) Remove front band lever shaft plug, if neces-
sary, from converter housing.
(21) Remove front band lever shaft.
Fig. 21 Removing Oil Pump And Reaction Shaft
Support Assembly
1 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
2 - SLIDE HAMMER TOOLS C-3752
Fig. 22 Removing Front Band Strut
1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND
Fig. 23 Removing Front Band Lever
1 - FRONT BAND LEVER
21 - 162 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

(22) Remove front and rear clutch units as assem-
bly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 24).
(23) Lift front clutch off rear clutch (Fig. 25). Set
clutch units aside for overhaul.(24) Remove intermediate shaft thrust washer
from front end of shaft or from rear clutch hub (Fig.
26).
(25) Remove output shaft thrust plate from inter-
mediate shaft hub (Fig. 27).
(26) Slide front band off driving shell (Fig. 28) and
remove band from case.
Fig. 24 Removing Front/Rear Clutch Assemblies
1 - INPUT SHAFT
2 - FRONT CLUTCH
3 - REAR CLUTCH
Fig. 25 Separating Front/Rear Clutch Assemblies
1 - FRONT CLUTCH
2 - REAR CLUTCH
Fig. 26 Removing Intermediate Shaft Thrust Washer
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
Fig. 27 Removing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 163
AUTOMATIC TRANSMISSION - 42RE (Continued)

(27) Remove planetary geartrain as assembly (Fig.
29). Support geartrain with both hands during
removal. Do not allow machined surfaces on interme-
diate shaft or overdrive piston retainer to become
nicked or scratched.(28) If overdrive unit is not to be serviced, install
Alignment Shaft 6227-2 into the overdrive unit to
prevent misalignment of the overdrive clutches dur-
ing service of main transmission components.
(29) Loosen rear band adjusting screw 4-5 turns.
(30) Remove low-reverse drum snap-ring (Fig. 30).
(31) Remove low-reverse drum and reverse band.
(32) Remove overrunning clutch roller and spring
assembly as a unit (Fig. 31).
Fig. 29 Removing Planetary Geartrain And
Intermediate Shaft Assembly
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
Fig. 31 Overrunning Clutch Assembly Removal
1 - OVERRUNNING CLUTCH CAM
2 - REAR BAND REACTION PIN
3 - OVERRUNNING CLUTCH ASSEMBLY
Fig. 28 Front Band Removal
1 - DRIVING SHELL
2 - FRONT BAND
Fig. 30 Removing Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
21 - 164 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

(33) Compress front servo rod guide about 1/8 inch
with Valve Spring Compressor C-3422-B (Fig. 32).
(34) Remove front servo rod guide snap-ring. Exer-
cise caution when removing snap-ring. Servo bore
can be scratched or nicked if care is not exercised.
(35) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
(36) Compress rear servo spring retainer about
1/16 inch with Valve Spring Compressor C-3422-B
(Fig. 33).
(37) Remove rear servo spring retainer snap-ring.
Then remove compressor tools and remove rear servo
spring and piston.
(38) Inspect transmission components.
NOTE: To Service the overrunning clutch cam or
overdrive piston retainer, refer to the Overrunning
Clutch Cam service procedure in this section.
CLEANING
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components andcirculate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
Lubricate transmission parts with MopartATF +4,
type 9602, transmission fluid during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-GlydeŸ to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
Inspect the transmission bushings during overhaul.
Bushing condition is important as worn, scored bush-
ings contribute to low pressures, clutch slip and
accelerated wear of other components. However, do
not replace bushings as a matter of course. Replace
bushings only when they are actually worn, or
scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install, and
Fig. 32 Compressing Front Servo Rod Guide
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
Fig. 33 Compressing Rear Servo Spring
1 - FRONT SERVO SNAP-RING
2 - REAR SERVO SNAP-RING
3 - SPECIAL TOOL
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 165
AUTOMATIC TRANSMISSION - 42RE (Continued)

seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B.
Pre-sized service bushings are available for
replacement purposes. Only the sun gear bushings
are not serviced.
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
ASSEMBLY
Do not allow dirt, grease, or foreign material to
enter the case or transmission components during
assembly. Keep the transmission case and compo-
nents clean. Also make sure the tools and workbench
area used for assembly operations are equally clean.
Shop towels used for wiping off tools and hands
must be made fromlint freematerial. Lint will stick
to transmission parts and could interfere with valve
operation, or even restrict fluid passages.
Lubricate the transmission components with
Moparttransmission fluid during reassembly. Use
MopartDoor Ease, or Ru-GlydeŸ on seals and
O-rings to ease installation.
Petroleum jelly can also be used to hold thrust
washers, thrust plates and gaskets in position during
assembly. However,do notuse chassis grease, bear-
ing grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can
eventually block or restrict fluid passages and inter-
fere with valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission
components and subassemblies are easily installed by
hand when properly aligned.
If a part seems extremely difficult to install, it is
either misaligned or incorrectly assembled. Also ver-
ify that thrust washers, thrust plates and seal rings
are correctly positioned before assembly. These parts
can interfere with proper assembly if mis-positioned.
The planetary geartrain, front/rear clutch assem-
blies and oil pump are all much easier to install
when the transmission case is upright.
(1) Install rear servo piston, spring and retainer
(Fig. 34). Install spring on top of servo piston and
install retainer on top of spring.(2) Install front servo piston assembly, servo
spring and rod guide (Fig. 35).
(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap-ring (Fig. 36).
Fig. 34 Rear Servo Components
1 - SERVO PISTON
2 - PISTON SPRING
3 - SNAP-RING
4 - RETAINER
5 - PISTON SEAL
Fig. 35 Front Servo Components
1 - PISTON SEAL RINGS
2 - SERVO PISTON
3 - SNAP-RING
4 - ROD GUIDE
5 - SPRING
6 - ROD
21 - 166 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

(4) Lubricate clutch cam rollers with transmission
fluid.
(5) Install rear band in case (Fig. 37). Be sure twin
lugs on band are seated against reaction pin.(6) Install low-reverse drum and check overrun-
ning clutch operation as follows:
(a) Lubricate overrunning clutch race (on drum
hub) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start race (on drum
hub) into overrunning clutch rollers.
(d) Press drum rearward and turn it in clock-
wise direction until drum seats in overrunning
clutch (Fig. 38).
(e) Turn drum back and forth. Drum should
rotate freely in clockwise direction and lock in
counterclockwise direction (as viewed from front of
case).
Fig. 36 Compressing Front/Rear Servo Springs
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
Fig. 37 Rear Band Installation
1 - REAR BAND
Fig. 38 Installing Low-Reverse Drum
1 - REAR BAND
2 - LOW-REVERSE DRUM
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 167
AUTOMATIC TRANSMISSION - 42RE (Continued)

(7) Install snap-ring that secures low-reverse drum
to hub of overdrive piston retainer (Fig. 39).
(8) Install rear band lever and pivot pin (Fig. 40).
Align lever with pin bores in case and push pivot pin
into place.
(9) Install planetary geartrain assembly (Fig. 41).
(10)
Install thrust plate on intermediate shaft hub
(Fig. 42). Use petroleum jelly to hold thrust plate in
place.
Fig. 42 Installing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
Fig. 39 Installing Low-Reverse Drum Retaining
Snap-Ring
1 - LOW-REVERSE DRUM
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
Fig. 40 Rear Band Lever And Pivot Pin Installation
1 - REAR BAND LEVER
2 - LEVER PIVOT PIN
Fig. 41 Installing Planetary Geartrain
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
21 - 168 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)