Dodge Durango (DN). Manual — part 60

(3) Remove bolts attaching pump body to support

(Fig. 197).

(4) Separate support from pump housing (Fig.

198).

(5) Remove inner and outer gears from reaction

shaft support (Fig. 199).

(6) If pump seal was not removed during transmis-

sion disassembly, remove seal with punch and ham-
mer.

(7) Remove front clutch thrust washer from sup-

port hub (Fig. 200).

OIL PUMP BUSHING REPLACEMENT

(1) Remove

pump

bushing

with

Tool

Handle

C-4171 and Bushing Remover SP-3551 from Tool Set
C-3887-J (Fig. 201).

(2) Install new pump bushing with Tool Handle

C-4171 and Bushing Installer SP-5117 (Fig. 201).
Bushing should be flush with pump housing bore.

Fig. 196 Removing Pump Seal Ring

1 – PUMP HOUSING SEAL RING

Fig. 197 Pump Support Bolts

1 – REACTION SHAFT SUPPORT
2 – PUMP

Fig. 198 Separating Pump Housing From Reaction

Shaft Support

1 – REACTION SHAFT SUPPORT
2 – PUMP HOUSING

Fig. 199 Pump Gear Removal

1 – REACTION SHAFT SUPPORT
2 – INNER GEAR
3 – OUTER GEAR

Fig. 200 Support Hub Thrust Washer

1 – BUSHING
2 – REACTION SHAFT SUPPORT
3 – THRUST WASHER
4 – HUB

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DISASSEMBLY AND ASSEMBLY (Continued)

(3) Stake new pump bushing in two places with

blunt punch (Fig. 202). Remove burrs from stake
points with knife blade afterward.

REACTION SHAFT SUPPORT BUSHING REMOVAL

(1) Assemble Bushing Remover Tools SP-1191,

3633 and 5324 (Fig. 203). Do not clamp any part
of reaction shaft or support in vise.

(2) Hold Cup Tool SP-3633 firmly against reaction

shaft and thread remover SP-5324 into bushing as
far as possible by hand. Then thread remover tool 3-4
additional turns into bushing with a wrench.

(3) Turn remover tool hex nut down against

remover cup to pull bushing from shaft. Clean all
chips from shaft after bushing removal.

(4) Lightly grip old bushing in vise or with pliers

and back remover tool out of bushing.

(5) Assemble Bushing Installer Tools C-4171 and

SP-5325 (Fig. 203).

(6) Slide new bushing onto Installer Tool SP-5325.
(7) Position reaction shaft support upright on a

clean smooth surface.

(8) Align bushing in bore. Then tap bushing into

place until Bushing Installer SP-5325 bottoms.

(9) Clean reaction shaft support thoroughly after

installing bushing.

ASSEMBLY

(1) Lubricate gear bore in pump housing with

transmission fluid.

(2) Lubricate pump gears with transmission fluid.
(3) Support pump housing on wood blocks (Fig.

204).

(4) Install outer gear in pump housing (Fig. 204).

Gear can be installed either way (it is not a one-way
fit).

Fig. 201 Removing Oil Pump Bushing

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL SP-3551
3 – BUSHING
4 – SPECIAL TOOL SP-5117
5 – BUSHING
6 – SPECIAL TOOL C-4171
7 – PUMP HOUSING

Fig. 202 Staking Oil Pump Bushing

1 – NARROW BLADE
2 – BLUNT PUNCH
3 – TWO STAKES

Fig. 203 Replacing Reaction Shaft Support Bushing

1 – SPECIAL TOOL SP-1191
2 – SPECIAL TOOL SP-3633
3 – SPECIAL TOOL C-4171
4 – SPECIAL TOOL SP-5325
5 – REACTION SHAFT
6 – SPECIAL TOOL SP-5324
7 – BUSHING

DN

42/44RE AUTOMATIC TRANSMISSION

21 - 107

DISASSEMBLY AND ASSEMBLY (Continued)

(5) Install pump inner gear (Fig. 205).

CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter
(I.D.) is chamfered. Be sure the chamfered side
faces forward (to front of pump).

(6) Install new thrust washer on hub of reaction

shaft support. Lubricate washer with transmission
fluid or petroleum jelly.

(7) If reaction shaft seal rings are being replaced,

install new seal rings on support hub (Fig. 206).
Lubricate seal rings with transmission fluid or petro-
leum jelly after installation. Squeeze each ring until
ring ends are securely hooked together.

CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-

lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.

(8) Install reaction shaft support on pump housing

(Fig. 207).

(9) Align reaction support on pump housing. Use

alignment marks made at disassembly. Or, rotate
support until bolt holes in support and pump housing
are all aligned (holes are offset for one-way fit).

(10) Install all bolts that attach support to pump

housing. Then tighten bolts finger tight.

(11) Tighten support-to-pump bolts to required

torque as follows:

(a) Reverse pump assembly and install it in

transmission case. Position pump so bolts are fac-
ing out and are accessible.

(b) Secure pump assembly in case with 2 or 3

bolts, or with pilot studs.

(c) Tighten support-to-pump bolts to 20 N·m (15

ft. lbs.).

(d) Remove pump assembly from transmission

case.

Fig. 204 Supporting Pump And Installing Outer Gear

1 – OUTER GEAR
2 – PUMP HOUSING
3 – WOOD BLOCKS

Fig. 205 Pump Inner Gear Installation

1 – OUTER GEAR
2 – INNER GEAR

Fig. 206 Hub Seal Ring Position

1 – SEAL RINGS
2 – SUPPORT HUB

Fig. 207 Assembling Reaction Shaft Support And

Pump Housing

1 – PUMP HOUSING
2 – REACTION SHAFT SUPPORT

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DISASSEMBLY AND ASSEMBLY (Continued)

(12) Install new oil seal in pump with Special Tool

C-4193 and Tool Handle C-4171 (Fig. 208). Be sure
seal lip faces inward.

(13) Install new seal ring around pump housing.

Be sure seal is properly seated in groove.

(14) Lubricate lip of pump oil seal and O-ring seal

with transmission fluid.

FRONT CLUTCH

NOTE: The 42RE transmission uses four plates and
discs for the front clutch. The 44RE uses five plates
and discs for the front clutch. The front clutch
retainer is not interchangeable between these trans-
missions.

DISASSEMBLY

(1) Remove waved snap ring and remove pressure

plate, clutch plates and clutch discs (Fig. 209).

(2) Compress clutch piston spring with Compressor

Tool C-3575-A (Fig. 210). Be sure legs of tool are

seated squarely on spring retainer before compress-
ing spring.

(3) Remove retainer snap ring and remove com-

pressor tool.

Fig. 208 Pump Oil Seal Installation

1 – PUMP BODY
2 – PUMP SEAL
3 – SPECIAL TOOL C-4193

Fig. 209 42RE Front Clutch Components

1 – RETAINER HUB SEAL
2 – CLUTCH PISTON
3 – PISTON SPRING
4 – SPRING RETAINER SNAP RING
5 – CLUTCH DISCS
6 – PRESSURE PLATE

7 – SNAP RING (WAVED)
8 – CLUTCH PLATES
9 – SPRING RETAINER
10 – PISTON SEAL
11 – FRONT CLUTCH RETAINER

DN

42/44RE AUTOMATIC TRANSMISSION

21 - 109

DISASSEMBLY AND ASSEMBLY (Continued)