Dodge Durango (DN). Manual — part 68

FRONT SERVO

Clean the servo piston components with solvent

and dry them with compressed air. Wipe the band
clean with lint free shop towels.

Replace the front band if distorted, lining is

burned, flaking off, or worn to the point where the
grooves in the lining material are no longer visible.

Inspect the servo components. Replace the springs

if collapsed, distorted or broken. Replace the guide,
rod and piston if cracked, bent, or worn. Discard the
servo snap ring if distorted or warped.

Check the servo piston bore for wear. If the bore is

severely scored, or damaged, it will be necessary to
replace the case.

Replace any servo component if doubt exists about

condition. Do not reuse suspect parts.

REAR SERVO

Remove and discard the servo piston seal ring (Fig.

304). Then clean the servo components with solvent
and dry with compressed air. Replace either spring if
collapsed, distorted or broken. Replace the plug and
piston if cracked, bent, or worn. Discard the servo
snap rings and use a new ones at assembly.

OIL PUMP AND REACTION SHAFT SUPPORT

(1) Clean pump and support components with sol-

vent and dry them with compressed air.

(2) Check condition of the seal rings and thrust

washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.

(3) Inspect the pump and support components.

Replace the pump or support if the seal ring grooves
or machined surfaces are worn, scored, pitted, or

damaged. Replace the pump gears if pitted, worn
chipped, or damaged.

(4) Inspect the pump bushing. Then check the

reaction shaft support bushing. Replace either bush-
ing only if heavily worn, scored or damaged. It is not
necessary to replace the bushings unless they are
actually damaged.

(5) Install the gears in the pump body and mea-

sure pump component clearances as follows:

(a) Clearance between outer gear and reaction

shaft housing should be 0.010 to 0.063 mm (0.0004
to 0.0025 in.). Clearance between inner gear and
reaction shaft housing should be 0.010 to 0.063
mm (0.0004 to 0.0025 in.). Both clearances can be
measured at the same time by:

(I) Installing the pump gears in the pump

housing.

(II) Position an appropriate piece of Plasti-

gage

y across both gears.

(III) Align the plastigage to a flat area on the

reaction shaft housing.

(IV) Install the reaction shaft to the pump

housing.

(V) Separate the reaction shaft housing from

the pump housing and measure the Plastigage

y

following the instructions supplied with it.
(b) Clearance between inner gear tooth and

outer gear should be 0.08 to 0.19 mm (0.0035 to
0.0075 in.). Measure clearance with an appropriate
feeler gauge.

(c) Clearance between outer gear and pump

housing should also be 0.010 to 0.19 mm (0.0035 to
0.0075 in.). Measure clearance with an appropriate
feeler gauge.

FRONT CLUTCH

Clean and inspect the front clutch components.

Replace the clutch discs if warped, worn, scored,
burned or charred, or if the facing is flaking off.
Replace the steel plates if heavily scored, warped, or
broken. Be sure the driving lugs on the plates are in
good condition. The lugs must not be bent, cracked or
damaged in any way.

Replace the clutch spring and spring retainer if

either is distorted, warped or broken.

Check the lug grooves in the clutch retainer. The

steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.

Check action of the check ball in the retainer (Fig.

305). The ball must move freely and not stick.

NOTE: Inspect the clutch retainer bushings care-
fully (Fig. 306). The retainer bushings are NOT ser-
viceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.

Fig. 304 Rear Servo Components

1 – SNAP RING
2 – PISTON SEAL
3 – PISTON PLUG
4 – SPRING RETAINER
5 – SNAP RING
6 – PISTON SPRING
7 – CUSHION SPRING
8 – PISTON

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CLEANING AND INSPECTION (Continued)

Inspect the piston and retainer seal surfaces for

nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.

REAR CLUTCH

Clean the clutch components with solvent and dry

them with compressed air. Do not use rags or shop
towels to dry any of the clutch parts. Lint from such
materials will adhere to component surfaces and
could restrict or block fluid passages after assembly.

Replace the clutch discs if warped, worn, scored,

burned/charred, the lugs are damaged, or if the fac-
ing is flaking off. Replace the top and bottom pres-
sure plates if scored, warped, or cracked. Be sure the
driving lugs on the pressure and clutch plates are
also in good condition. The lugs must not be bent,
cracked or damaged in any way.

Replace the piston spring and wave spring if either

part is distorted, warped or broken.

Check the lug grooves in the clutch retainer. The

clutch and pressure plates should slide freely in the
slots. Replace the retainer if the grooves are worn or
damaged. Also check action of the check balls in the
retainer and piston. Each check ball must move
freely and not stick.

Replace the retainer bushing if worn, scored, or

doubt exists about bushing condition.

Inspect the piston and retainer seal surfaces for

nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.

Check condition of the fiber thrust washer and

metal output shaft thrust washer. Replace either
washer if worn or damaged.

Check condition of the seal rings on the input shaft

and clutch retainer hub. Replace the seal rings only
if worn, distorted, or damaged. The input shaft front
seal ring is teflon with chamfered ends. The rear ring
is metal with interlocking ends.

Check the input shaft for wear, or damage. Replace

the shaft if worn, scored or damaged in any way.

PLANETARY GEARTRAIN

Clean the planetary components in solvent and dry

them with compressed air.

Check

sun

gear

and

driving

shell

condition.

Replace the gear if damaged or if the bushings are
scored or worn. The bushings are not serviceable.
Replace the driving shell if worn, cracked or dam-
aged.

Replace planetary gear sets if gears, pinion pins, or

carrier are damaged in any way. Replace the annulus
gears and supports if either component is worn or
damaged.

Inspect the geartrain spacers, thrust plates, snap

rings, and thrust washers. Replace any of these parts
that are worn, distorted or damaged. Do not attempt
to reuse these parts.

The planetary gear thrust washers are different

sizes. The large diameter washers go on the front
planetary and the smaller washers go on the rear
planetary. All the washers have four locating tabs on
them. These tabs fit in the holes or slots provided in
each planetary gear.

Inspect the output shaft carefully. Pay particular

attention to the machined bushing/bearing surfaces
on the shaft and the governor valve shaft bore at the
shaft rear.

Replace the output shaft if the machined surfaces

are scored, pitted, or damaged in any way. Also
replace the shaft if the splines are damaged, or
exhibits cracks at any location (especially at the gov-
ernor valve shaft bore).

Fig. 305 Front Clutch Piston Retainer Check Ball

Location

1 – RETAINER CHECK BALL

Fig. 306 Retainer Bushing Location/Inspection

1 – FRONT CLUTCH RETAINER BUSHINGS (NON-

SERVICEABLE)

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42/44RE AUTOMATIC TRANSMISSION

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CLEANING AND INSPECTION (Continued)

The annulus gears can be removed from their sup-

ports if necessary. Just remove the snap rings and
separate the two parts when replacement is neces-
sary. In addition, the annulus gear bushings can be
replaced if severely worn, or scored. However it is not
necessary to replace the bushings if they only exhibit
normal wear. Check bushing fit on the output shaft
to be sure.

OVERDRIVE UNIT

Clean the geartrain and case components with sol-

vent. Dry all parts except the bearings with com-
pressed air. Allow bearings to air dry.

Do not use shop towels for wiping parts dry unless

the towels are made from a lint-free material. A suf-
ficient quantity of lint (from shop towels, cloths, rags,
etc.) could plug the transmission filter and fluid pas-
sages.

Discard the old case gasket and seals. Do not

attempt to salvage these parts. They are not reus-
able. Replace any of the overdrive unit snap rings if
distorted or damaged.

Minor nicks or scratches on components can be

smoothed with crocus cloth. However, do not attempt
to reduce severe scoring on any components with
abrasive materials. Replace severely scored compo-
nents; do not try to salvage them.

Check condition of the park lock components and

the overdrive case.

Replace the case if cracked, scored, or damaged.

Replace the park lock pawl, plug, or spring if worn or
damaged. Be sure the bullet at the end of the park
lock rod is in good condition. Replace the rod if the
bullet is worn or the rod itself is bent or distorted.
Do not attempt to straighten the rod.

Check the bushings in the overdrive case. Replace

the bushings if severely scored or worn. Also replace
the case seal if loose, distorted, or damaged.

Examine the overdrive and direct clutch discs and

plates. Replace the discs if the facing is worn,
severely scored, or burned and flaking off. Replace
the clutch plates if worn, heavily scored, or cracked.
Check the lugs on the clutch plates for wear. The
plates should slide freely in the drum. Replace the
plates or drum if binding occurs.

Check condition of the annulus gear, direct clutch

hub, clutch drum and clutch spring. Replace the gear,
hub and drum if worn or damaged. Replace the
spring if collapsed, distorted, or cracked.

Be sure the splines and lugs on the gear, drum and

hub are in good condition. The clutch plates and
discs should slide freely in these components.

Inspect the thrust bearings and spring plate.

Replace the plate if worn or scored. Replace the bear-
ings if rough, noisy, brinnelled, or worn.

Inspect the planetary gear assembly and the sun

gear and bushings. If either the sun gear or the
bushings are damaged, replace the gear and bush-
ings as an assembly. The gear and bushings are not
serviced separately.

The planetary carrier and pinions must be in good

condition. Also be sure the pinion pins are secure and
in good condition. Replace the carrier if worn or dam-
aged.

Inspect the overrunning clutch and race. The race

surface should be smooth and free of scores. Replace
the overrunning clutch assembly or the race if either
assembly is worn or damaged in any way.

Inspect the output shaft and governor components.

Replace the shaft pilot bushing and inner bushing if
damaged. Replace either shaft bearing if rough or
noisy. Replace the bearing snap rings if distorted or
cracked.

Check the machined surfaces on the output shaft.

These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.

Inspect the output shaft bushings. The small bush-

ing is the intermediate shaft pilot bushing. The large
bushing is the overrunning clutch hub bushing.
Replace either bushing if scored, pitted, cracked, or
worn.

ADJUSTMENTS

TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT

The transmission throttle valve is operated by a

cam on the valve body throttle lever. The throttle
lever is actuated by a cable connected to the engine
throttle body lever (Fig. 307). A retaining clip at the
engine-end of the cable is removed to provide for
cable adjustment. The retaining clip is then installed
back onto the throttle valve cable to lock in the
adjustment.

A correctly adjusted throttle valve cable, will cause

the throttle lever on the transmission to move simul-
taneously with the throttle body lever from the idle
position. Proper adjustment allows simultaneous
movement without causing the transmission throttle
lever to move ahead of, or lag behind the throttle
body lever.

THROTTLE VALVE CABLE ADJUSTMENT CHECK

(1) Turn ignition key to OFF position.
(2) Remove air cleaner.
(3) Slide cable off attachment stud on throttle body

lever (Fig. 307).

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CLEANING AND INSPECTION (Continued)

(4) Verify that throttle body lever is at curb idle

position. Then verify that transmission throttle lever
is also at idle (full forward) position.

(5) Compare position of cable end to attachment

stud on throttle body lever:

(a) Cable end and attachment stud should be

aligned (or centered on one another) to within 1
mm (0.039 in.) in either direction.

(b) If cable end and attachment stud are mis-

aligned (off center), cable will have to be adjusted
as described in following procedure.
(6) Reconnect cable end to attachment stud. Then

with aid of a helper, observe movement of transmis-
sion throttle lever and lever on throttle body.

(a) If both levers move simultaneously from idle

to half-throttle and back to idle position, adjust-
ment is correct.

(b) If transmission throttle lever moves ahead of,

or lags behind throttle body lever, cable adjustment
will be necessary. Or, if throttle body lever pre-
vents transmission lever from returning to closed
position, cable adjustment will be necessary.

THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE

(1) Turn ignition switch to OFF position and shift

into Park.

(2) Remove air cleaner.

(3) Disconnect cable end from attachment stud on

throttle body. Carefully slide cable off stud. Do
not pull or pry cable off.

(4) Verify that transmission throttle lever is in idle

(full forward) position. Then be sure lever on throttle
body is at curb idle position.

(5) Insert a small screwdriver under edge of

retaining clip and remove retaining clip.

(6) Center cable end on attachment stud to within

1 mm (0.039 in.).

NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.

(7) Install retaining clip onto cable housing.
(8) Check cable adjustment. Be sure transmission

throttle lever and lever on throttle body move simul-
taneously and as described in cable adjustment
checking procedure.

GEARSHIFT CABLE

Check adjustment by starting the engine in Park

and Neutral. Adjustment is OK if the engine starts
only in these positions. Adjustment is incorrect if the
engine starts in one but not both positions. If the
engine starts in any position other than Park or Neu-
tral, or if the engine will not start at all, the park/
neutral position switch may be faulty.

Gearshift Adjustment Procedure

(1) Shift transmission into Park.
(2) Release cable adjuster lock (underneath the

power brake booster) (Fig. 308) to unlock cable.

(3) Raise vehicle.
(4) Slide cable eyelet off transmission shift lever.
(5) Verify transmission shift lever is in Park

detent by moving lever fully rearward. Last rearward
detent is Park position.

(6) Verify positive engagement of transmission

park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.

(7) Slide cable eyelet onto transmission shift lever.
(8) Lower

vehicle

and

check

engine

starting.

Engine should start only in Park and Neutral.

(9) Lock shift cable by pressing cable adjuster

clamp down until it snaps into place.

BAND ADJUSTMENTS

FRONT BAND ADJUSTMENT

The front (kickdown) band adjusting screw is

located on the left side of the transmission case
above the manual valve and throttle valve levers.

Fig. 307 Throttle Valve Cable Attachment —At

Engine

1 – THROTTLE VALVE CABLE
2 – CABLE BRACKET
3 – THROTTLE BODY LEVER
4 – ACCELERATOR CABLE
5 – SPEED CONTROL CABLE

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42/44RE AUTOMATIC TRANSMISSION

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ADJUSTMENTS (Continued)