transmission DODGE RAM 2001 Service Repair Manual

(5) Clean the mating surfaces of shift tower and
isolator plate with suitable wax and grease remover.
(6) Apply Mopar Gasket Maker or equivalent to
sealing surface of the transmission case. Do not over
apply sealant.
(7) Install isolator plate onto the transmission case
metal side down.
(8) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(9) Verify that the shift tower, isolator plate and
the shift socket are properly aligned.
(10) Install bolts to hold the shift tower to the iso-
lator plate and the transmission case. Tighten bolts
to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(11) Install shift boot and bezel.
(12) Connect battery negative cable.
FOUR WHEEL DRIVE
(1) Install and secure transfer case on the trans-
mission jack.
(2) Raise and align transfer case input gear with
transmission mainshaft.
(3) Move transfer case forward and seat it on
adapter.
(4) Install and tighten transfer case mounting nuts
to 41-47 N´m (30-35 ft. lbs.) if case has 3/8 studs. If
case has 5/16 studs tighten to 30-41 N´m (22-30 ft.
lbs.).
(5) Connect transfer case shift lever to range lever
on transfer case.(6) Install propeller shafts with reference marks
aligned.
(7) Fill transmission with required lubricant.
Check lubricant level in transfer case and add lubri-
cant if necessary.
(8) Install transfer case skid plate, if equipped,
and crossmember. Tighten attaching bolts/nuts to 41
N´m (30 ft. lbs.).
(9) Install exhaust system components.
(10) Remove support and lower vehicle.
(11) Shift transmission into third gear.
(12) Clean the mating surfaces of shift tower, iso-
lator plate, and transmission case with suitable wax
and grease remover.
(13) Apply Mopar Gasket Maker or equivalent to
the sealing surface of the transmission case. Do not
over apply sealant.
(14) Install isolator plate onto the transmission
case, metal side down.
(15) Install shift tower onto the isolator plate. No
sealant is necessary between the shift tower and top
of isolator plate.
(16) Verify that the shift tower, isolator plate and
the shift tower bushings are properly aligned.
(17) Install the bolts to hold the shift tower to the
isolator plate and the transmission case. Tighten the
shift tower bolts to 10.2±11.25 N´m (7.5±8.3 ft. lbs.).
(18) Install shift lever boot and bezel.
(19) Connect battery negative cable.
SPECIFICATIONS
SPECIFICATIONS - NV5600
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Crossover Cam and
Detent48 35 -
Bolt, Input Retainer 28 20 -
Bolt, 5-6 Crossover Bracket 28 20 -
Bolt, Clutch Housing 48 35 -
Bolt, Extension/Adapter Housing 48 35 -
Bolt, Shift Tower 9 7 80
Switch, Back-up Lamp 28 20 -
Bolt, Shift Blocker 55 41 -
Bolt, PTO Cover 40 30 -
Pivot, Clutch Release Lever 22 16 -
Plug, Fill 30 22 -
Nut, Output Shaft 339 250 -
21 - 126 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

SPECIAL TOOLS
NV5600 MANUAL TRANSMISSION
Remover, BushingÐ8155
Installer, BushingÐ8156
Handle UniversalÐC-4171
Installer, SealÐC-3972-A
Installer, SealÐ8154
Wrench, Output ShaftÐ8226
Wrench, Splined SocketÐ6984
Wrench, Splined SocketÐ6984
Puller, Bearing and GearÐ6444
BR/BEMANUAL - NV5600 21 - 127
MANUAL - NV5600 (Continued)

ADAPTER HOUSING SEAL
REMOVAL
(1) Remove the propeller shaft.
(2) Remove the transfer case.
(3) Remove adapter housing seal with a pry tool or
a slide hammer mounted screw.
INSTALLATION
(1) Install extension housing seal with Installer
8154 and Handle C-4171.
(2) Install propeller shaft with reference marks
aligned.
EXTENSION HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Mark propeller shaft and pinion yoke for
installation reference and remove the propeller shaft.
(3) Remove the extension housing seal with a suit-
able pry tool or a slide hammer mounted screw.
(4) Remove the extension housing bushing with
Remover 8155 (Fig. 98).
INSTALLATION
(1) Install extension housing bushing with
Installer 8156 (Fig. 99) and Handle C-4171.
(2) Install adapter housing seal with Installer
8154 and Handle C-4171 (Fig. 100).
(3) Install transfer case and propeller shaft(s).
(4) Check and fill transmission.
(5) Remove support and lower vehicle.
SHIFT COVER
REMOVAL
(1) Shift transmission into Neutral.
(2) Unscrew and remove the shift lever extension
from the shift
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on the shift lever.
(4) Remove the bolts holding the shift tower to the
isolator plate and transmission gear case.
(5) Remove the shift tower (Fig. 101) and isolator
plate (Fig. 102) from the transmission.
Fig. 99 Extension Housing Bushing Installer
1 - HANDLE
2 - INSTALLER
3 - BUSHING
Fig. 100 Extension Housing Seal Installer
1 - INSTALLER
2 - HANDLE
Fig. 98 Extension Housing
1 - REMOVER
21 - 132 MANUAL - NV5600BR/BE

INSTALLATION
(1) Shift transmission into third gear.
(2) Clean the mating surfaces of shift tower, isola-
tor plate, and transmission gear case with suitable
wax and grease remover.
(3) Apply MopartGasket Maker, or equivalent, to
the sealing surface of the transmission. Do not over
apply sealant.
(4) Install the isolator plate onto the transmission,
metal side down.
(5) Install the shift tower onto the isolator plate.
No sealant is necessary between the shift tower and
top of the isolator plate.
(6) Verify that the shift tower, isolator plate, and
the shift tower bushings are properly aligned.
(7) Install the bolts to hold the shift tower to the
isolator plate and the transmission gear case.
Tighten the shift tower bolts to 8±10 N´m (7±9 ft.
lbs.).
(8) Install the shift lever extension, shift boot, and
bezel.
Fig. 101 Remove Shift Tower
1 - SHIFT TOWER
2 - TRANSMISSION
Fig. 102 Remove Shift Tower Isolator Plate
1 - ISOLATOR PLATE
2 - TRANSMISSION
BR/BEMANUAL - NV5600 21 - 133
SHIFT COVER (Continued)

AUTOMATIC TRANSMISSION - 42RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 42RE
DESCRIPTION..........................135
OPERATION............................137
DIAGNOSIS AND TESTING................143
AUTOMATIC TRANSMISSION.............143
PRELIMINARY........................143
ROAD TESTING.......................143
HYDRAULIC PRESSURE TEST...........144
AIR CHECKING TRANSMISSION CLUTCH
AND BAND OPERATION.................147
CONVERTER HOUSING FLUID LEAK......148
DIAGNOSIS CHARTS...................149
STANDARD PROCEDURE.................159
ALUMINUM THREAD REPAIR.............159
REMOVAL.............................159
DISASSEMBLY..........................160
CLEANING.............................165
INSPECTION...........................165
ASSEMBLY............................166
INSTALLATION..........................173
SCHEMATICS AND DIAGRAMS.............174
SPECIFICATIONS........................186
SPECIAL TOOLS........................188
ACCUMULATOR
DESCRIPTION..........................191
OPERATION............................191
INSPECTION...........................192
BANDS
DESCRIPTION..........................192
OPERATION............................192
ADJUSTMENTS.........................193
ELECTRONIC GOVERNOR
DESCRIPTION..........................194
OPERATION............................194
REMOVAL.............................196
INSTALLATION..........................197
EXTENSION HOUSING BUSHING
REMOVAL.............................198
INSTALLATION..........................198
EXTENSION HOUSING SEAL
REMOVAL.............................198
INSTALLATION..........................198
FLUID AND FILTER
DIAGNOSIS AND TESTING................199
EFFECTS OF INCORRECT FLUID LEVEL . . . 199
CAUSES OF BURNT FLUID..............199
FLUID CONTAMINATION................199
STANDARD PROCEDURE.................199
FLUID LEVEL CHECK...................199FLUID AND FILTER REPLACEMENT.......201
TRANSMISSION FILL...................201
FRONT CLUTCH
DESCRIPTION..........................202
OPERATION............................202
DISASSEMBLY..........................202
INSPECTION...........................205
ASSEMBLY............................206
FRONT SERVO
DESCRIPTION..........................206
OPERATION............................207
DISASSEMBLY..........................207
CLEANING.............................207
INSPECTION...........................207
ASSEMBLY............................208
OIL PUMP
DESCRIPTION..........................208
OPERATION............................208
STANDARD PROCEDURE.................209
OIL PUMP VOLUME CHECK..............209
DISASSEMBLY..........................209
CLEANING.............................211
INSPECTION...........................211
ASSEMBLY............................212
OUTPUT SHAFT FRONT BEARING
REMOVAL.............................213
INSTALLATION..........................213
OUTPUT SHAFT REAR BEARING
REMOVAL.............................213
INSTALLATION..........................213
OVERDRIVE CLUTCH
DESCRIPTION..........................214
OPERATION............................214
OVERDRIVE OFF SWITCH
DESCRIPTION..........................215
OPERATION............................215
DIAGNOSIS AND TESTING................215
OVERDRIVE ELECTRICAL CONTROLS.....215
REMOVAL.............................215
INSTALLATION..........................215
OVERDRIVE UNIT
REMOVAL.............................216
DISASSEMBLY..........................217
CLEANING.............................224
INSPECTION...........................224
ASSEMBLY............................225
INSTALLATION..........................234
21 - 134 AUTOMATIC TRANSMISSION - 42REBR/BE

OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION..........................235
OPERATION............................235
DISASSEMBLY..........................235
CLEANING.............................236
INSPECTION...........................236
ASSEMBLY............................236
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING................237
PARK/NEUTRAL POSITION SWITCH.......237
REMOVAL.............................238
INSTALLATION..........................238
PISTONS
DESCRIPTION..........................238
OPERATION............................238
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION..........................240
OPERATION............................240
DISASSEMBLY..........................240
INSPECTION...........................241
ASSEMBLY............................241
REAR CLUTCH
DESCRIPTION..........................246
OPERATION............................246
DISASSEMBLY..........................247
CLEANING.............................247
INSPECTION...........................248
ASSEMBLY............................248
REAR SERVO
DESCRIPTION..........................250
OPERATION............................250
DISASSEMBLY..........................251
CLEANING.............................251
ASSEMBLY............................251
SHIFT MECHANISM
DESCRIPTION..........................251OPERATION............................251
ADJUSTMENTS.........................252
SOLENOID
DESCRIPTION..........................252
OPERATION............................253
SPEED SENSOR
DESCRIPTION..........................253
OPERATION............................253
THROTTLE VALVE CABLE
DESCRIPTION..........................253
ADJUSTMENTS.........................254
TORQUE CONVERTER
DESCRIPTION..........................256
OPERATION............................260
REMOVAL.............................261
INSTALLATION..........................261
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION..........................262
OPERATION............................262
STANDARD PROCEDURE.................262
TORQUE CONVERTER DRAINBACK VALVE . 262
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION..........................262
OPERATION............................262
VALVE BODY
DESCRIPTION..........................263
OPERATION............................267
REMOVAL.............................281
DISASSEMBLY..........................282
CLEANING.............................293
INSPECTION...........................293
ASSEMBLY............................294
INSTALLATION..........................303
ADJUSTMENTS.........................304
AUTOMATIC TRANSMISSION -
42RE
DESCRIPTION
The 42RE is a four speed fully automatic transmis-
sion (Fig. 1) with an electronic governor. The 42RE is
equipped with a lock-up clutch in the torque con-
verter. First through third gear ranges are provided
by the clutches, bands, overrunning clutch, and plan-
etary gear sets in the transmission. Fourth gear
range is provided by the overdrive unit that contains
an overdrive clutch, direct clutch, planetary gear set,
and overrunning clutch.
The transmission contains a front, rear, and direct
clutch which function as the input driving compo-
nents. It also contains the kickdown (front) and thelow/reverse (rear) bands which, along with the over-
running clutch and overdrive clutch, serve as the
holding components. The driving and holding compo-
nents combine to select the necessary planetary gear
components, in the front, rear, or overdrive planetary
gear set, transfer the engine power from the input
shaft through to the output shaft.
The valve body is mounted to the lower side of the
transmission and contains the valves to control pres-
sure regulation, fluid flow control, and clutch/band
application. The oil pump is mounted at the front of
the transmission and is driven by the torque con-
verter hub. The pump supplies the oil pressure nec-
essary for clutch/band actuation and transmission
lubrication.
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 135

Fig. 1 42RE Transmission
21 - 136 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas-
ket surface (Fig. 2). Refer to this information when
ordering replacement parts.
GEAR RATIOS The 42RE gear ratios are:
1st.................................2.74:1
2nd................................1.54:1
3rd.................................1.00:1
4th.................................0.69:1
Rev.................................2.21:1
OPERATION
The application of each driving or holding compo-
nent is controlled by the valve body based upon the
manual lever position, throttle pressure, and gover-
nor pressure. The governor pressure is a variable
pressure input to the valve body and is one of the
signals that a shift is necessary. First through fourth
gear are obtained by selectively applying and releas-
ing the different clutches and bands. Engine power is
thereby routed to the various planetary gear assem-
blies which combine with the overrunning clutch
assemblies to generate the different gear ratios. The
torque converter clutch is hydraulically applied and
is released when fluid is vented from the hydraulic
circuit by the torque converter control (TCC) solenoid
on the valve body. The torque converter clutch is con-
trolled by the Powertrain Control Module (PCM). The
torque converter clutch engages in fourth gear, and
in third gear under various conditions, such as when
the O/D switch is OFF, when the vehicle is cruising
on a level surface after the vehicle has warmed up.
The torque converter clutch will disengage momen-
tarily when an increase in engine load is sensed by
the PCM, such as when the vehicle begins to go
uphill or the throttle pressure is increased. The
torque converter clutch feature increases fuel econ-
omy and reduces the transmission fluid temperature.
Since the overdrive clutch is applied in fourth gear
only and the direct clutch is applied in all ranges
except fourth gear, the transmission operation for
park, neutral, and first through third gear will be
described first. Once these powerflows are described,
the third to fourth shift sequence will be described.
1 - CONVERTER CLUTCH 15 - HOUSING
2 - TORQUE CONVERTER 16 - REAR BEARING
3 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 17 - OUTPUT SHAFT
4 - FRONT BAND 18 - SEAL
5 - FRONT CLUTCH 19 - OVERDRIVE OVERRUNNING CLUTCH
6 - DRIVING SHELL 20 - OVERDRIVE PLANETARY GEAR
7 - REAR BAND 21 - DIRECT CLUTCH SPRING
8 - TRANSMISSION OVERRUNNING CLUTCH 22 - OVERDRIVE CLUTCH PISTON
9 - OVERDRIVE UNIT 23 - VALVE BODY ASSEMBLY
10 - PISTON RETAINER 24 - FILTER
11 - OVERDRIVE CLUTCH 25 - FRONT PLANETARY GEAR
12 - DIRECT CLUTCH 26 - REAR CLUTCH
13 - INTERMEDIATE SHAFT 27 - TRANSMISSION
14 - FRONT BEARING 28 - REAR PLANETARY GEAR
Fig. 2 Transmission Part And Serial Number
Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 137
AUTOMATIC TRANSMISSION - 42RE (Continued)

PARK POWERFLOW
As the engine is running and the crankshaft is
rotating, the flexplate and torque converter, which
are also bolted to it, are all rotating in a clockwise
direction as viewed from the front of the engine. The
notched hub of the torque converter is connected to
the oil pump's internal gear, supplying the transmis-
sion with oil pressure. As the converter turns, it
turns the input shaft in a clockwise direction. As the
input shaft is rotating, the front clutch hub-rear
clutch retainer and all their associated parts are also
rotating, all being directly connected to the input
shaft. The power flow from the engine through the
front clutch hub and rear clutch retainer stops at the
rear clutch retainer. Therefore, no power flow to the
output shaft occurs because no clutches are applied.
The only mechanism in use at this time is the park-
ing sprag (Fig. 3), which locks the parking gear on
the output shaft to the transmission case.
NEUTRAL POWERFLOW
With the gear selector in the NEUTRAL position
(Fig. 4), the power flow of the transmission is essen-
tially the same as in the park position. The only
operational difference is that the parking sprag has
been disengaged, unlocking the output shaft from the
transmission case and allowing it to move freely.
Fig. 3 Park Powerflow
1 - PAWL ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5-PAWL
21 - 138 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

REVERSE POWERFLOW
When the gear selector is moved into the
REVERSE position (Fig. 5), the front clutch and the
rear band are applied. With the application of the
front clutch, engine torque is applied to the sun gear,
turning it in a clockwise direction. The clockwise
rotation of the sun gear causes the rear planet pin-
ions to rotate against engine rotation in a counter-
clockwise direction. The rear band is holding the low
reverse drum, which is splined to the rear carrier.
Since the rear carrier is being held, the torque fromthe planet pinions is transferred to the rear annulus
gear, which is splined to the output shaft. The output
shaft in turn rotates with the annulus gear in a
counterclockwise direction giving a reverse gear out-
put. The entire transmission of torque is applied to
the rear planetary gearset only. Although there is
torque input to the front gearset through the sun
gear, no other member of the gearset is being held.
During the entire reverse stage of operation, the
front planetary gears are in an idling condition.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 139
AUTOMATIC TRANSMISSION - 42RE (Continued)