Dodge Durango (DN). Manual — part 67

Fig. 297 42RE Overdrive Clutch Components

1 – REACTION PLATE
2 – PRESSURE PLATE

Fig. 298 Overdrive Clutch Pack Retaining Ring

Installation

1 – OVERDRIVE CLUTCH PACK RETAINING RING

Fig. 299 Shaft End Play Measurement

1 – SPECIAL TOOL 6312
2 – SPECIAL TOOL 6311
3 – SPECIAL TOOL C-4962

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DISASSEMBLY AND ASSEMBLY (Continued)

OD THRUST PLATE SELECTION

(1) Place overdrive unit in vertical position. Mount

it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.

(2) Determine correct thickness overdrive piston

thrust plate as follows:

(a) Position Gauge Tool 6311 across face of over-

drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 301).

(b) Measure distance to clutch hub thrust bear-

ing seat at four points 90° apart. Then average
measurements by adding them and dividing by 4.

(c) Select and install required thrust plate from

information in thrust plate chart (Fig. 302).
(3) Leave Alignment Tool 6227-2 in place. Tool will

keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on trans-
mission.

(4) Transmission speed sensor can be installed at

this time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.

OVERDRIVE PISTON ASSEMBLY

(1) Install new seals on over drive piston.
(2) Stand transmission case upright on bellhous-

ing.

(3) Position Guide Ring 8114-1 on outer edge of

overdrive piston retainer.

(4) Position Seal Guide 8114-2 on inner edge of

overdrive piston retainer.

(5) Install overdrive piston in overdrive piston

retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.

(a) Aligning locating lugs on overdrive piston to

the two mating holes in retainer.

(b) Lubricate overdrive piston seals with Mopar

t

Door Ease, or equivalent.

(c) Install piston over Seal Guide 8114–2 and

inside Guide Ring 8114–1.

(d) Push

overdrive

piston

into

position

in

retainer.

(e) Verify that the locating lugs entered the lug

bores in the retainer.
(6) Install intermediate shaft spacer on intermedi-

ate shaft.

(7) Install overdrive piston thrust plate on over-

drive piston.

(8) Install overdrive piston thrust bearing on over-

drive piston.

(9) Install transmission speed sensor and O-ring

seal in overdrive case (Fig. 242).

Fig. 300 Intermediate Shaft End Play Spacer

Selection

Fig. 301 Overdrive Piston Thrust Plate Measurement

1 – SPECIAL TOOL 6311
2 – DIRECT CLUTCH HUB THRUST BEARING SEAT
3 – SPECIAL TOOL C-4962

Fig. 302 Overdrive Piston Thrust Plate Selection

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42/44RE AUTOMATIC TRANSMISSION

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DISASSEMBLY AND ASSEMBLY (Continued)

CLEANING AND INSPECTION

VALVE BODY

Clean the valve housings, valves, plugs, springs,

and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution.

Do not immerse any of the electrical components in

cleaning solution. Clean the governor solenoid and
sensor and the dual solenoid and harness assembly
by wiping them off with dry shop towels only.

Dry all except the electrical parts with compressed

air. Make sure all passages are clean and free from
obstructions. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.

Wipe the governor pressure sensor and solenoid

valve with dry, lint free shop towels only. The O-rings
on the sensor and solenoid valve are the only service-
able components. Be sure the vent ports in the sole-
noid valve are open and not blocked by dirt or debris.
Replace the valve and/or sensor only when DRB scan
tool diagnosis indicates this is necessary. Or, if either
part

has

sustained

physical

damage

(dented,

deformed, broken, etc.).

CAUTION: Do not turn the small screw at the end
of the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.

Inspect the throttle and manual valve levers and

shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.

Inspect all of the valve body mating surfaces for

scratches, nicks, burrs, or distortion. Use a straight-
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.

Minor distortion of a valve body mating surface

may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-
face. If distortion is severe or any surfaces are
heavily scored, the valve body will have to be
replaced.

CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the

dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.

Inspect the valves and plugs for scratches, burrs,

nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth
but do not round off the edges of the valve or
plug lands. Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.

Inspect all the valve and plug bores in the valve

body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.

Check the two separator plates for distortion or

damage of any kind. Inspect the upper housing,
lower housing, 3-4 accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean
and clear. Check condition of the upper housing and
transfer plate check balls as well. The check balls
and ball seats must not be worn or damaged.

Trial fit each valve and plug in its bore to check

freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores.

Valve body bores do not change dimensionally with

use. If the valve body functioned correctly when new,
it will continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.

The only serviceable valve body components are

listed below. The remaining valve body components
are serviced only as part of a complete valve body
assembly. Serviceable parts are:

• dual solenoid and harness assembly

• solenoid gasket

• solenoid case connector O-rings and shoulder

bolt

• switch valve and spring

• pressure adjusting screw and bracket assembly

• throttle lever

• manual lever and shaft seal

• throttle lever shaft seal, washer, and E-clip

• fluid filter and screws

• detent ball and spring

• valve body screws

• governor pressure solenoid

• governor pressure sensor and retaining clip

• park lock rod and E-clip

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TRANSMISSION

GENERAL INFORMATION

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
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. Low cost of the sun gear assembly
makes it easier to simply replace the gear and bush-
ings as an assembly.

Heli-Coil inserts can be used to repair damaged,

stripped or worn threads in aluminum parts. These
inserts are available from most automotive parts
suppliers. Stainless steel inserts are recommended.

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.

Lubricate transmission parts with Mopar

t ATF

Plus 3, Type 7176, transmission fluid during over-
haul and assembly. Use petroleum jelly, Mopar

t Door

Ease, or Ru-Glyde to prelubricate seals, O-rings, and
thrust washers. Petroleum jelly can also be used to
hold parts in place during reassembly.

TRANSMISSION CASE CLEANING AND
INSPECTION

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 and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.

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.

OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER

Clean the overrunning clutch assembly, clutch cam,

low-reverse drum, and overdrive piston retainer in
solvent. Dry them with compressed air after clean-
ing.

Inspect condition of each clutch part after cleaning.

Replace the overrunning clutch roller and spring
assembly if any rollers or springs are worn or dam-
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.

Replace the low-reverse drum if the clutch race,

roller surface or inside diameter is scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.

Examine the overdrive piston retainer carefully for

wear, cracks, scoring or other damage. Be sure the
retainer hub is a snug fit in the case and drum.
Replace the retainer if worn or damaged.

ACCUMULATOR

Inspect the accumulator piston and seal rings (Fig.

303). Replace the seal rings if worn or cut. Replace
the piston if chipped or cracked.

Check condition of the accumulator inner and

outer springs (Fig. 303). Replace the springs if the
coils are cracked, distorted or collapsed.

Fig. 303 Accumulator Components

1 – INNER SPRING
2 – ACCUMULATOR PISTON
3 – OUTER SPRING
4 – SEAL RINGS

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42/44RE AUTOMATIC TRANSMISSION

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CLEANING AND INSPECTION (Continued)