Dodge Durango (DN). Manual — part 65

(10) Remove snap ring that secures annulus gear

on output shaft (Fig. 268). Use two screwdrivers to
unseat and work snap ring out of groove as shown.

(11) Remove annulus gear from output shaft (Fig.

269). Use rawhide or plastic mallet to tap gear off
shaft.

GEAR CASE AND PARK LOCK DISASSEMBLY

(1) Remove locating ring from gear case.
(2) Remove park pawl shaft retaining bolt and

remove shaft, pawl and spring.

(3) Remove reaction plug snap ring and remove

reaction plug.

(4) Remove output shaft seal.

ASSEMBLY

GEARTRAIN AND DIRECT CLUTCH ASSEMBLY

(1) Soak direct clutch and overdrive clutch discs in

Mopar

t ATF Plus 3, type 7176, transmission fluid.

Allow discs to soak for 10-20 minutes.

(2) Install new pilot bushing and clutch hub bush-

ing in output shaft if necessary (Fig. 270). Lubricate
bushings with petroleum jelly, or transmission fluid.

(3) Install

annulus

gear

on

output

shaft,

if

removed. Then install annulus gear retaining snap
ring (Fig. 271).

Fig. 271 Annulus Gear Installation

1 – SNAP RING
2 – OUTPUT SHAFT FRONT BEARING
3 – ANNULUS GEAR

Fig. 268 Annulus Gear Snap Ring Removal

1 – OUTPUT SHAFT
2 – ANNULUS GEAR
3 – SNAP RING

Fig. 269 Annulus Gear Removal

1 – OUTPUT SHAFT
2 – ANNULUS GEAR

Fig. 270 Output Shaft Pilot Bushing

1 – OUTPUT SHAFT HUB
2 – OVERRUNNING CLUTCH HUB BUSHING
3 – INTERMEDIATE SHAFT PILOT BUSHING

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DISASSEMBLY AND ASSEMBLY (Continued)

(4) Align and install clutch drum on annulus gear

(Fig. 272). Be sure drum is engaged in annulus gear
lugs.

(5) Install clutch drum outer retaining ring (Fig.

272).

(6) Slide clutch drum forward and install inner

retaining ring (Fig. 273).

(7) Install rear bearing and snap ring on output

shaft (Fig. 274). Be sure locating ring groove in bear-
ing is toward rear.

(8) Install overrunning clutch on hub (Fig. 275).

Note that clutch only fits one way. Shoulder on

clutch should seat in small recess at edge of
hub.

(9) Install thrust bearing on overrunning clutch

hub. Use generous amount of petroleum jelly to hold
bearing in place for installation. Bearing fits one
way only. Be sure bearing is seated squarely
against hub. Reinstall bearing if it does not
seat squarely.

(10) Install overrunning clutch in output shaft

(Fig. 276). Insert snap ring pliers in hub splines.
Expand pliers to grip hub. Then install assembly
with counterclockwise, twisting motion.

(11) Install planetary gear in annulus gear (Fig.

277). Be sure planetary pinions are fully seated
in annulus gear before proceeding.

(12) Coat planetary thrust bearing and bearing

contact surface of spring plate with generous amount
of petroleum jelly. This will help hold bearing in
place during installation.

(13) Install planetary thrust bearing on sun gear

(Fig. 278). Slide bearing onto gear and seat it against

Fig. 272 Clutch Drum And Outer Retaining Ring

Installation

1 – ANNULUS GEAR
2 – OUTER SNAP RING
3 – CLUTCH DRUM

Fig. 273 Clutch Drum Inner Retaining Ring

Installation

1 – ANNULUS GEAR
2 – INNER SNAP RING
3 – CLUTCH DRUM

Fig. 274 Rear Bearing And Snap Ring Installation

1 – REAR BEARING
2 – SNAP RING

Fig. 275 Assembling Overrunning Clutch And Hub

1 – CLUTCH HUB
2 – OVERRUNNING CLUTCH

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DISASSEMBLY AND ASSEMBLY (Continued)

spring plate as shown. Bearing fits one way only.
If it does not seat squarely against spring plate,
remove and reposition bearing.

(14) Install assembled sun gear, spring plate and

thrust bearing (Fig. 279). Be sure sun gear and
thrust bearing are fully seated before proceeding.

(15) Mount assembled output shaft, annulus gear,

and clutch drum in shop press. Direct clutch spring,
hub and clutch pack are easier to install with assem-
bly mounted in press.

(16) Align splines in hubs of planetary gear and

overrunning clutch with Alignment tool 6227-2 (Fig.
280). Insert tool through sun gear and into splines of
both hubs. Be sure alignment tool is fully seated
before proceeding.

(17) Install direct clutch spring (Fig. 281). Be sure

spring is properly seated on spring plate.

Fig. 276 Overrunning Clutch Installation

1 – CLUTCH DRUM
2 – OVERRUNNING CLUTCH ASSEMBLY
3 – EXPANDING-TYPE SNAP RING PLIERS
4 – CLUTCH DRUM
5 – ANNULUS GEAR
6 – OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT

SHAFT

Fig. 277 Planetary Gear Installation

1 – PLANETARY GEAR
2 – ANNULUS GEAR

Fig. 278 Planetary Thrust Bearing Installation

1 – SPRING PLATE
2 – PLANETARY THRUST BEARING
3 – SUN GEAR

Fig. 279 Sun Gear Installation

1 – SUN GEAR AND SPRING PLATE ASSEMBLY

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DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The 42RE transmission has 6 direct clutch
discs and 5 clutch plates. The 44RE transmission
has 8 direct clutch discs and 7 clutch plates.

(18) Assemble and install direct clutch pack on

hub as follows:

(a) Assemble clutch pack components (Fig. 282)

or (Fig. 283).

Fig. 280 Alignment Tool Installation

1 – SPECIAL TOOL 6227–2
2 – PRESS PLATES
3 – ASSEMBLED DRUM AND ANNULUS GEAR
4 – SUN GEAR

Fig. 281 Direct Clutch Spring Installation

1 – SPECIAL TOOL 6227–2
2 – DIRECT CLUTCH SPRING
3 – CLUTCH HUB
4 – PRESS PLATES

Fig. 282 42RE Direct Clutch Pack Components

1 – REACTION PLATE

2 – PRESSURE PLATE

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DISASSEMBLY AND ASSEMBLY (Continued)