2007 Dodge Nitro R/T
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- Jeffry Chandler
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1 ASSEMBLY AUTOMATIC TRANSMISSION - 42RLE NOTE: If the transmission assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM QUICK LEARN Procedure using the scan tool. Fig. 18: 42RLE Bearing Orientation 1 - THRUST BEARING NO THRUST BEARING NO THRUST BEARING NO NEEDLE BEARING NO THRUST BEARING NO NEEDLE BEARING NO THRUST BEARING NO.4 -
2 Fig. 19: Bearing Cup Installation Special Tool A 1. Install the output bearing cups using Installer 5050A. See Fig. 19
3 Fig. 20: Removing/Installing Piston Retainer Gasket 1 - GASKET HOLES MUST LINE UP 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET 2. Install low/reverse piston retainer gasket (2). See Fig. 20.
4 Fig. 21: Installing Low/Reverse Piston Retainer 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - GASKET 3. Install low/reverse piston retainer (1). See Fig. 21.
5 Fig. 22: Installing Low/Reverse Piston Retainer-To-Case Screws 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - SCREWDRIVER 3 - TORX-LOC SCREWS 4. Install low/reverse piston retainer-to-case screws (3) and torque to 5 N.m (45 in. lbs.). See Fig. 22.
6 Fig. 23: Installing Low/Reverse Clutch Piston 1 - LOW/REVERSE CLUTCH PISTON 2 - D-RING SEAL 3 - D-RING SEAL NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly. 5. Install low/reverse clutch piston (1). See Fig. 23.
7 Fig. 24: Assembled Guide Bracket 1 - GUIDE BRACKET 2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN) 3 - PAWL 6. Assemble guide bracket (1) assembly as shown, if necessary. See Fig. 24.
8 Fig. 25: Installing Guide Bracket Pivot Pin 1 - PIVOT PIN 2 - GUIDE BRACKET ASSEMBLY CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case. 7. Install guide bracket pivot pin (1). See Fig Install park sprag pivot retaining screw and torque to 4.5 N.m (40 in. lbs.).
9 Fig. 26: Installing Low/Reverse Piston Belleville Spring 1 - LOW/REVERSE PISTON RETURN SPRING 2 - PISTON 9. Install low/reverse piston belleville spring (1) into position. See Fig. 26
10 Fig. 27: Installing And Loading Low/Reverse Spring With Compressor Tool 5058A-3, 5059A And Disc 6057 To Facilitate Snap Ring Installation 1 - LOW/REVERSE CLUTCH RETURN SPRING 2 - SNAP RING (INSTALL AS SHOWN) 3 - COMPRESSOR 5058A COMPRESSOR 5059A 5 - DISC Install and load low/reverse spring with compressor tool 5058A-3 (3), 5059A (4) and disc 6057 (5) as shown in Fig. 27 to facilitate snap ring (2) installation.
11 Fig. 28: Installing Low/Reverse Clutch Snap Ring 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN) 2 - SNAP RING PLIERS 3 - DISC Install snap ring (1) and remove compressor tool. See Fig. 28
12
13 Fig. 29: Installing Rear Carrier Front Bearing Cone 1 - ARBOR PRESS 2 - UNIVERSAL HANDLE C INSTALLER REAR CARRIER 12. Install rear carrier (4) front bearing cone. See Fig. 29 Fig. 30: Installing Rear Output Shaft Bearing Cone And Support Plate 6618A 1 - SUPPORT PLATE 6618-A 2 - REAR OUTPUT SHAFT BEARING 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)
14 Transmission case 13. PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and Support Plate 6618A (1). See Fig. 30. Fig. 31: Installing Support Plate 1 - SUPPORT PLATE 6618-A 14. Install Support Plate 6618A (1). See Fig. 31. Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws. 15. 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 Support Plate 6618A. Ensure your press table has clearance for the output shaft.
15 Fig. 32: Installing Shim On Output Shaft 1 - SHIM 2 - OUTPUT SHAFT 16. Install shim (1) on output shaft (2). See Fig. 32. 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.
16 Fig. 33: Install Output Shaft/Rear Carrier Into Rear Bearing 1 - UNIVERSAL HANDLE C-4171 AND HANDLE EXTENSION C DISC MD Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use Disc MD (2) and Universal Handle C-4171 and Handle Extension C (1) to press shaft into rear bearing. See Fig. 33.
17 Fig. 34: Checking Turning Torque Of Output Shaft 1 - TORQUE WRENCH 2 - WRENCH 6498-A 3 - OUTPUT SHAFT NUT CAUTION: Do not re-use old output shaft nut because the removed stake weakens the nut flange. Using Wrenches 6497 and 6498-A, install new output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.). 18. Check the turning torque (1) of the output shaft. See Fig. 34. The shaft should have 1 to 8 in. lbs. of
18 turning torque. If the turning torque is higher than 8 in. 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. Fig. 35: Identifying Arbor Press, Staking Tool & New Nut 1 - ARBOR PRESS 2 - STAKING TOOL NEW NUT CAUTION: Failure to stake nut could allow the nut to back-off during use.
19 19. The new nut (3) must be staked after the correct turning torque is obtained. See Fig. 35. Use Staking Tool 6639 (2) to stake output shaft nut. Fig. 36: Identifying Bottomed In Slot & Correctly Staked Nut 1 - BOTTOMED IN SLOT 2 - CORRECTLY STAKED NUT 20. Verify that the nut has been properly staked to the output shaft. See Fig. 36.
20 Fig. 37: Installing Low/Reverse Clutch Pack 1 - CLUTCH PLATES (5) 2 - CLUTCH DISCS (5) 21. Install low/reverse clutch pack (1, 2). See Fig. 37. Leave uppermost disc out to facilitate snap ring installation.
21 Fig. 38: Installing Low/Reverse Reaction Plate Snap Ring 1 - SCREWDRIVER 2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING 3 - DO NOT SCRATCH CLUTCH PLATE 22. Install low/reverse reaction plate snap ring (2). See Fig. 38.
22 Fig. 39: Installing One Low/Reverse Clutch Disc 1 - ONE DISC FROM LOW/REVERSE CLUTCH 23. Install one low/reverse clutch disc (1). See Fig. 39.
23 Fig. 40: Installing Low/Reverse Reaction Plate With Flat Side Up 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP) 24. Install low/reverse reaction plate (1) with flat side up. See Fig. 40
24 Fig. 41: Installing New Tapered Snap Ring (Tapered Side Out) 1 - SCREWDRIVER 2 - TAPERED SNAP RING (INSTALL AS SHOWN) 25. Install a new tapered snap ring (2) (tapered side out). See Fig. 41.
25 Fig. 42: Proper Snap Ring Orientation 26. Make sure that the snap ring ends are oriented as shown. See Fig. 42.
26 Fig. 43: Checking Low/Reverse Clutch Clearance 1 - DIAL INDICATOR 2 - DIAL INDICATOR TIP TOOL HOOK TOOL 27. Measure low/reverse clutch pack. Set up dial indicator (1) as shown. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. See Fig. 43.Low/Reverse clutch pack clearance is 0.84 to 1.60 mm (0.033 to inch). 28. Select the proper low/reverse reaction plate to achieve specifications.
27 Fig. 44: Installing 2/4 Clutch Pack 1 - CLUTCH PLATE (4) 2 - CLUTCH DISC (4) 29. Install 2/4 clutch pack (1, 2). See Fig. 44.
28 Fig. 45: Installing 2/4 Clutch Belleville Spring 1-2/4 CLUTCH RETURN SPRING NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly. 30. Install 2/4 clutch belleville spring (1). See Fig. 45.
29 Fig. 46: Verifying Proper Orientation Of Return Spring To 2/4 Retainer 1 - NOTE POSITION 2 - RETURN SPRING 3-2/4 CLUTCH RETAINER 31. Verify the proper orientation of the return spring (2) to the 2/4 retainer (3). See Fig. 46.
30 Fig. 47: Installing 2/4 Clutch Retainer 1-2/4 CLUTCH RETAINER 32. Install 2/4 clutch retainer (1). See Fig. 47.
31 Fig. 48: Compressing 2/4 Clutch 1 - TOOL SCREWDRIVER 3 - SNAP RING 4-2/4 CLUTCH RETAINER NOTE: Verify that Compressor 5058A (1) is centered properly over the 2/4 clutch retainer (4) before compressing. If necessary, fasten the bar from Compressor 5058A to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly. 33. Set up Compressor 5058 (1) as shown. Compress 2/4 clutch just enough to facilitate snap ring installation. See Fig. 48.
32 Fig. 49: Checking 2/4 Clutch Clearance 1 - DIAL INDICATOR 2 - HOOK TOOL 3 - DIAL INDICATOR TIP TOOL Measure 2/4 clutch clearance: Set up dial indicator (1) as shown. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. See Fig. 49.The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to inch). If not within specifications, the clutch is not assembled properly or is excessively worn. There is no adjustment for the 2/4 clutch clearance.
33 Fig. 50: Identifying Rear Sun Gear & No. 7 Needle Bearing 1 - #7 BEARING 2 - REAR SUN GEAR 35. Install the #7 needle bearing (1) to the rear sun gear (2). See Fig. 50. The number 7 needle bearing has three antireversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
34 Fig. 51: Installing Rear Sun Gear And #7 Needle Bearing 1 - #7 NEEDLE BEARING 2 - REAR SUN GEAR 36. Install rear sun gear (2) and #7 needle bearing (1). See Fig. 51.
35 Fig. 52: Installing Front Carrier/Rear Annulus Assembly And #6 Needle Bearing 1 - #6 NEEDLE BEARING 2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL). 37. Install front carrier/rear annulus assembly (2) and #6 needle bearing (1). See Fig. 52.
36 Fig. 53: Installing Front Sun Gear Assembly And #4 Thrust Washer 1 - FRONT SUN GEAR ASSEMBLY 2 - #4 THRUST WASHER (FOUR TABS) 38. Install front sun gear assembly (1) and #4 thrust washer (2). See Fig. 53.
37 Fig. 54: Installing #4 Thrust Plate Using Petrolatum To Hold Into Position 1 - OVERDRIVE SHAFT ASSEMBLY 2 - #4 THRUST PLATE (SELECT) 3 - PETROLATUM FOR RETENTION 39. Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate. 40. Install #4 thrust plate (2) using petrolatum to hold into position. See Fig Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole. If the speed sensor tone wheel is not centered in the opening, the input clutches assembly is not seated properly.
38 Fig. 55: Removing Oil Pump O-Ring And Installing Oil Pump And Gasket To Transmission 1 - OIL PUMP ASSEMBLY 2 - O-RING 42. Remove the oil pump o-ring (2) and install oil pump and gasket to transmission. See Fig. 55.Use screwin dowels or Phillips head screwdrivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.
39 Fig. 56: Measuring Input Shaft End Play Using End Play Set TOOL TOOL TOOL C-3339A 43. Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate. 44. Set up and measure endplay using End Play Set 8266 (1, 2) and Dial Indicator Set C3339A (3) as shown. See Fig Measure input shaft end play. Input shaft end play must be to mm (0.005 to inch). For example, if end play reading is inch, select No. 4 Thrust Plate which is to thick. This should provide an input shaft end play reading of inch, which is within specifications.
40 Fig. 57: Installing Input Clutch Assembly With Proper Thrust Plate 1 - INPUT CLUTCH ASSEMBLY 46. Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate. 47. Install input clutch assembly (1) with proper thrust plate. See Fig. 57.
41 Fig. 58: Installing #1 Caged Needle Bearing 1 - #1 CAGED NEEDLE BEARING 2 - NOTE: TANGED SIDE OUT 48. Install #1 caged needle bearing (1). See Fig. 58.
42 Fig. 59: Replacing Cooler By-Pass Valve 1 - BYPASS VALVE CAUTION: By-pass valve MUST be replaced if transmission failure occurs. 49. Replace cooler by-pass valve (1) if transmission failure has occurred. See Fig. 59. NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or Phillips screwdrivers.
43 Fig. 60: Installing Oil Pump Gasket 1 - BELLHOUSING 2 - OIL PUMP GASKET 50. Install oil pump gasket (2). See Fig. 60.
44 Fig. 61: Installing Oil Pump And Torque Oil Pump-To-Case Bolts 1 - BOLTS 2 - OIL PUMP 51. Install oil pump (2) and torque oil pump-to-case bolts (1) to 30 N.m (265 in. lbs.). Do not reuse original oil pump bolts. See Fig. 61.
45 Fig. 62: Installing Low/Reverse Accumulator 1 - ACCUMULATOR PISTON 52. Install low/reverse accumulator (1) as shown. See Fig. 62.
46 Fig. 63: Installing Low/Reverse Accumulator Plug 1 - ADJUSTABLE PLIERS 2 - PLUG 53. Install low/reverse accumulator plug (2). See Fig. 63.
47 Fig. 64: Installing Low/Reverse Accumulator Snap Ring 1 - SNAP RING 2 - LOW/REVERSE ACCUMULATOR 54. Install low/reverse accumulator snap ring (1). See Fig. 64.
48 Fig. 65: Installing Underdrive And Overdrive Accumulators And Springs 1 - OVERDRIVE PISTON AND SPRING 2 - UNDERDRIVE PISTON AND SPRING 55. Install underdrive (2) and overdrive (1) accumulators and springs. See Fig. 65.
49 Fig. 66: Removing/Installing Valve Body 1 - VALVE BODY CAUTION: Do not handle the valve body by the manual shaft. Damage could result. 56. Install valve body (1) into place as shown. See Fig. 66.
50 Fig. 67: Removing/Installing Valve Body Bolts 1 - BOLTS 57. Install seven (7) valve body-to-case bolts (1) and torque to 12 N.m (105 in. lbs.). See Fig. 67.
51 Fig. 68: Removing/Installing Transmission Oil Filter 1 - TRANSMISSION FILTER 58. Install transmission oil filter (1). See Fig. 68. Tighten the bolts to 5 N.m (45 in. lbs.).
52 Fig. 69: Removing/Installing Transmission Oil Pan 1 - TRANSMISSION OIL PAN 59. Install transmission oil pan (1) with a bead of Mopar ATF RTV. See Fig. 69.
53 Fig. 70: Locating Oil Pan Bolts & Pressure Ports 1 - FRONT DRIVESHAFT 2 - PRESSURE PORTS 3 - TRANSMISSION CASE 4 - TRANSMISSION OIL PAN 5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE 6 - FIRST TRANSMISSION OIL PAN BOLT
54 61. Install both speed sensors (1, 2) into the transmission case. Torque the speed sensor bolts to 9 N.m (80 in Dodge Nitro R/T 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. See Fig Install and torque the oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.). Fig. 71: Locating Input Speed, Output Speed and Transmission Range Sensors 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - TRANSMISSION RANGE SENSOR NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar Lock & Seal Adhesive.
55 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 C-3339A to transmission bell housing with its plunger seated against end of input shaft. See Fig. 72. Install tool (2), (1) and move input shaft in and out to obtain end play reading. Input shaft end play must be to mm (0.005 to inch). If not within specifications, make the necessary thrust plate adjustment Dodge Nitro R/T lbs.). See Fig. 71. Fig. 72: Measuring Input Shaft End Play Using End Play Set TOOL TOOL TOOL C-3339A
56 63. On 4X2 transmissions, perform the following, if necessary: Fig. 73: Removing/Installing Extension Shaft Bearing 1 - EXTENSION SHAFT 2 - BEARING Install the extension shaft bearing (2) onto the extension shaft. See Fig. 73.
57 Fig. 74: Removing/Installing Extension Shaft Bearing Retaining Ring 1 - EXTENSION SHAFT 2 - BEARING 3 - RETAINING RING Install the extension shaft bearing retaining ring (3) onto the extension shaft (1). See Fig. 74.
58 Fig. 75: Installing Extension Shaft And Bearing Assembly Into Extension Housing 1 - EXTENSION HOUSING 2 - EXTENSION SHAFT 3 - BEARING Install the extension shaft (2) and bearing assembly (3) into the extension housing (1). See Fig. 75.
59 Fig. 76: Installing Extension Shaft Bearing Snap Ring Into Extension Housing 1 - EXTENSION SHAFT 2 - BEARING 3 - SNAP RING Install the extension shaft bearing snap ring (3) into the extension housing. See Fig. 76.
60 Fig. 77: Identifying Extension Shaft, Bearing & Snap Ring 1 - EXTENSION SHAFT 2 - BEARING 3 - SNAP RING Verify that the extension shaft snap ring (3) is fully engaged in the snap ring groove. See Fig. 77.
61 Fig. 78: Inspecting Lube Tube Grommet For Damage 1 - HOUSING 2 - LUBE TUBE 3 - GROMMET 4 - PRY SLOTS 64. Inspect the lube tube grommet (2) for damage. If the grommet lip is damaged, it will need to be replaced. See Fig. 78.
62 Fig. 79: Installing Adapter Housing Onto Transmission Case 1 - TRANSMISSION CASE 2 - ADAPTER HOUSING 65. Install the 4X4 stub shaft onto the transmission output shaft. 66. Place a bead of Mopar ATF RTV on the rear surface of the transmission case for the adapter/extension housing. 67. Install the adapter housing (2) onto the transmission case, 4X4 vehicles only. See Fig. 79.
63 Fig. 80: Installing Extension Housing Onto Transmission Case 1 - TRANSMISSION CASE 2 - EXTENSION HOUSING 68. Install the extension housing (2) onto the transmission case, 4X2 vehicles only. See Fig. 80.
64 Fig. 81: Adapter Housing Fasteners 1 - STUD, ADAPTER/EXTENSION 2 - TRANSMISSION MOUNT FASTENERS (4) 3 - TRANSMISSION MOUNT 4 - TRANSMISSION CASE 5 - NUT, EXHAUST HANGER BRACKET (2) 6 - STUD, ADAPTER/EXTENSION 7 - TRANSMISSION OIL PAN 8 - BOLT, ADAPTER/EXTENSION (2)
65 NOTE: Before installing the lowermost four adapter/extension housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mopar Lock & Seal Adhesive. Fig. 82: Installing Adapter Housing Bolts 1 - TRANSMISSION CASE 2 - ADAPTER HOUSING 3 - BOLTS 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 N.m (40 ft.lbs.). See Fig. 82.
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