lock DODGE RAM SRT-10 2006 Service Repair Manual

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AUTOMATIC TRANSMISSION 42RLE - SERVICE
INFORMATION
DESCRIPTION ............................... 391
OPERATION ................................. 393
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION ............... 398
ROAD TEST ............................... 399
HYDRAULIC PRESSURE TESTS............ 400
CLUTCH AIR PRESSURE TESTS........... 402
FLUID LEAKAGE.......................... 403
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR .......................... 404
REMOVAL ................................... 404
DISASSEMBLY .............................. 406
ASSEMBLY .................................. 428
INSTALLATION .............................. 451
SCHEMATICS AND DIAGRAMS
42RLE - WITHOUT VARIABLE LINE
PRESSURE............................... 455
42RLE - WITH VARIABLE LINE PRESSURE . . 469
SPECIFICATIONS
42RLE AUTOMATIC TRANSMISSION ........ 479
SPECIAL TOOLS
42RLE AUTOMATIC TRANSMISSION ........ 481
ACCUMULATOR
DESCRIPTION ............................... 485
OPERATION ................................. 486
SEAL-ADAPTER HOUSING
REMOVAL ................................... 487
INSTALLATION .............................. 487
BEARINGS
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURES.... 488
MECHANISM-BRAKE TRANSMISSION SHIFT
INTERLOCK
DESCRIPTION ............................... 489
OPERATION ................................. 489
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK ......... 489
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK ......................... 489
CLUTCHES-DRIVING
DESCRIPTION ............................... 491
OPERATION ................................. 491
SEAL-EXTENSION HOUSING
REMOVAL ................................... 492
INSTALLATION .............................. 492
FLUID AND FILTER
DIAGNOSIS AND TESTING
CAUSES OF BURNT FLUID ................. 493EFFECTS OF INCORRECT FLUID LEVEL . . . . 493
FLUID CONTAMINATION ................... 493
STANDARD PROCEDURE
FLUID LEVEL CHECK...................... 493
FLUID/FILTER SERVICE .................... 494
TRANSMISSION FILL ...................... 495
CABLE-GEARSHIFT
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE .................................... 496
REMOVAL ................................... 496
INSTALLATION .............................. 497
ADJUSTMENTS - GEARSHIFT CABLE ......... 498
CLUTCHES-HOLDING
DESCRIPTION ............................... 499
OPERATION ................................. 499
ASSEMBLY-INPUT CLUTCH
DISASSEMBLY .............................. 500
ASSEMBLY .................................. 509
SENSOR-INPUT SPEED
DESCRIPTION ............................... 523
OPERATION ................................. 523
REMOVAL ................................... 523
INSTALLATION .............................. 524
SENSOR-VARIABLE LINE PRESSURE
DESCRIPTION ............................... 525
OPERATION ................................. 525
REMOVAL ................................... 525
INSTALLATION .............................. 526
PUMP-OIL
DESCRIPTION ............................... 527
OPERATION ................................. 527
DISASSEMBLY .............................. 527
ASSEMBLY .................................. 529
SENSOR-OUTPUT SPEED
DESCRIPTION ............................... 530
OPERATION ................................. 530
REMOVAL ................................... 530
INSTALLATION .............................. 531
GEARTRAIN-PLANETARY
DESCRIPTION ............................... 532
OPERATION ................................. 532
SEAL-OIL PUMP
REMOVAL ................................... 533
INSTALLATION .............................. 533
SOLENOID-PRESSURE CONTROL
DESCRIPTION ............................... 534
OPERATION ................................. 534
REMOVAL ................................... 534
INSTALLATION .............................. 535

THIRDGEARPOWERFLOW
In third gear, two input clutches are applied to provide torque input: the underdrive clutch (1) and overdrive clutch
(2). The underdrive clutch rotates the rear sun gear, while the overdrive clutch rotates the front carrier/rear annulus
assembly. The result is two components (rear sun gear and rear annulus gear) rotating at the same speed and in
the same direction. This effectively locks the entire planetary gearset together and is rotated as one unit. The gear
ratio in third is 1:1.
Third Gear Powerflow
1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun)
2 - OVERDRIVE CLUTCH APPLIED (Turns Front Carrier/Rear Annulus)

OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply passage and watch for the push/pull piston to move forward. The
piston should return to its starting position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply passage and watch for the push/pull piston to move rearward. The
piston should return to its starting position when the air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed hole passage. Look in thearea where the low/reverse piston con-
tacts the first separator plate. Watch carefully for the piston to move forward. The piston should return to its original
position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its opera-
tion is checked by function. Use an air nozzle (2) to
apply air pressure is to the low/reverse or the 2/4
clutch opening in Test Plate 6599-1 (2). This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers to
turn the input shaft. Next apply air pressure to the
underdrive clutch. The input shaft should not rotate
with hand torque. Release the air pressure and con-
firm that the input shaft will rotate.
FLUID LEAKAGE
FLUID LEAKAGE - TORQUE CONVERTER HOUSING AREA
When diagnosing converter housing (5) fluid leaks,
three actions must be taken before repair:
1. Verify proper transmission fluid level.
2. Verify that the leak originates from the converter
housing area and is transmission fluid.
3. Determine the true source of the leak.
Fluid leakage at or around the torque converter area
may originate from an engine oil leak (7). The area
should be examined closely. Factory fill fluid is red
and, therefore, can be distinguished from engine oil.
Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess fluid
spilled during factory fill, or fill after repair. Converter
housing leaks have several potential sources. Through
careful observation, a leak source can be identified
before removing the transmission for repair.
Pump seal (1) leaks tend to move along the drive hub and onto the rear of the converter. Pump o-ring or pump
body leaks follow the same path as a seal leak. Pump attaching bolt (3) leaksare generally deposited on the inside
of the converter housing (5) and not on the converter itself. Pump seal (1) or gasket (4) leaks usually travel down
the inside of the converter housing.

16. Remove the starter motor.
17. Remove the engine to transmission collar.
18. Rotate crankshaft in clockwise direction until con-
verter bolts are accessible. Then remove bolts
one at a time. Rotate crankshaft with socket
wrench on dampener bolt.
19. Disconnect the transmission vent hose from the
transmission.
20. Remove transfer case. (Refer to 21 - TRANSMIS-
SION/TRANSFER CASE - REMOVAL)
21. Support rear of engine with safety stand or jack.
22. Raise transmission slightly with service jack to
relieve load on crossmember and supports.
23. Remove bolts securing rear support and cushion
to transmission and crossmember.
24. Remove bolts attaching crossmember to frame
and remove crossmember.
25. Disconnect transmission fluid cooler lines (1) at
transmission fittings (3) and clips (2).
26. Remove all remaining converter housing bolts.
27. Carefully work transmission and torque converter
assembly rearward off engine block dowels.
28. Hold torque converter in place during transmission
removal.
29. Lower transmission and remove assembly from
under the vehicle.
30. To remove torque converter, carefully slide torque
converter out of the transmission.
DISASSEMBLY
NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to
perform the Quick Learn Procedure using the scan tool (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE).
NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as the unit might then fail.
Before disassembling transmission, move the shift lever clockwise as faras it will go and then remove the shift
lever.

NOTE: Verify that Compressor 5058A (1) is cen-
tered properly over the 2/4 clutch retainer (4)
before compressing. If necessary, fasten the
5058A bar to the bellhousing flange with any com-
bination of locking pliers and bolts to center the
tool properly.
37. Install and load Compressor 5058A to remove the
2/4 clutch retainer snap ring (3).
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
38. Remove the 2/4 clutch retainer (1).
39. Remove the 2/4 clutch return spring (1).

31. Verify the proper orientation of the return spring
(2) to the 2/4 retainer (3).
32. Install 2/4 clutch retainer (1).
NOTE: Verify that Compressor 5058A (1) is cen-
tered properly over the 2/4 clutch retainer (4)
before compressing. If necessary, fasten the
5058A bar to the bellhousing flange with any com-
bination of locking pliers and bolts to center the
tool properly.
33. Set up Compressor 5058A (1) as shown. Com-
press 2/4 clutch just enough to facilitate snap ring
installation.

NOTE: Before installing the oil pan bolt in the bolt
hole located between the torque converter clutch
on and U/D clutch pressure tap circuits , it will be
necessary to replenish the sealing patch on the
bolt using MOPAR
Lock & Seal Adhesive.
60. Install and torque the oil pan-to-case bolts to 20
Nꞏm (14.5 ft. lbs.).
NOTE: Before installing either speed sensor bolt,
it will be necessary to replentish the sealing patch
on the bolt using Mopar
Lock & Seal Adhesive.
61. Install both speed sensors (1, 2) into the transmis-
sion case. Torque the speed sensor bolts to 9
Nꞏm (80 in. lbs.).
62. As a final check of the transmission, measure the
input shaft end play. This will indicate when a #4
thrust plate change is required. The #4 thrust
plate is located behind the overdrive clutch hub.
Attach a dial indicator to transmission bell housing
with its plunger seated against end of input shaft.
Move input shaft in and out to obtain end play
reading.Input shaft end play must be 0.127 to
0.635 mm (0.005 to 0.025 inch).If not within
specifications, make the necessary thrust plate
adjustment.

65. Install the 4X4 stub shaft onto the transmission
output shaft.
66. Place a bead of Mopar
ATF RTV on the rear sur-
face of the transmission case for the adapter/ex-
tension housing.
67. Install the adapter housing (2) onto the transmis-
sion case, 4X4 vehicles only.
68. Install the extension housing (2) onto the trans-
mission case, 4X2vehicles only.
NOTE: Before installing thelowermost four adapt-
er/extension housing bolts , it will be necessary to
replenish the sealing patch on the bolts using
MOPAR
Lock & Seal Adhesive.

69. Install the bolts that hold the adapter or extension
housing onto the transmission case. Be sure to
install any stud bolts to their original locations.
Tighten the bolts to 54 Nꞏm (40 ft.lbs.).
INSTALLATION
NOTE: Check torque converter hub and hub drive flats for sharp edges burrs,scratches, or nicks. Polish
the hub and flats with 320/400 grit paper and crocus cloth if necessary. Thehub must be smooth to avoid
damaging pump seal at installation.
1. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift
lever and shift cable bracket, from the original transmission onto the replacement transmission.
2. Lubricate oil pump seal lip with transmission fluid.
3. Align converter and oil pump.
4. Carefully insert converter in oil pump. Then rotate
converter back and forth until fully seated in pump
gears.
5. Check converter seating with steel scale (1) and
straightedge (2). Surface of converter lugs should
be at least 13mm (1/2 in.) to rear of straightedge
when converter is fully seated.
6. Temporarily secure converter with C-clamp.
7. Position transmission on jack and secure it with chains.
8. Check condition of converter driveplate. Replace the plate if cracked,distorted or damaged.Also be sure trans-
mission dowel pins are seated in engine block and protrude far enough to holdtransmissioninalign-
ment.
9. Apply a light coating of Mopar
High Temp Grease to the torque converter hub pocket in the rear pocket of the
engine’s crankshaft.
10. Raise transmission and align the torque converter with the drive plateand transmission converter housing with
the engine block.
11. Move transmission forward. Then raise, lower or tilt transmission to align the converter housing with engine
block dowels.

12. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft.
Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the
transmission.
13. Install two bolts to attach the transmission to the engine.
14. Install remaining torque converter housing to engine bolts. Tighten to 68 Nꞏm (50 ft.lbs.).
15. Install transfer case, if equipped. Tighten transfer case nuts to 35 Nꞏm (26 ft.lbs.).
16. Install rear transmission crossmember. Tighten crossmember to framebolts to 68 Nꞏm (50 ft.lbs.).
17. Install rear support to transmission. Tighten bolts to 47 Nꞏm (35 ft.lbs.).
18. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten
clevis bracket to crossmember bolts to 47 Nꞏm (35 ft.lbs.). Tighten the clevis bracket to rear support bolt to 68
Nꞏm (50 ft.lbs.).
19. Connect gearshift cable (1) to support bracket (2)
and transmission manual lever (3).
20. Connect the input (1) and output (2) speed sensor
and the transmission range sensor (5).
21. Connect the variable line pressure connector (4),
if equipped.